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JP2005281924A - Nonwoven fabric manufacturing method and nonwoven fabric - Google Patents

Nonwoven fabric manufacturing method and nonwoven fabric Download PDF

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Publication number
JP2005281924A
JP2005281924A JP2004100404A JP2004100404A JP2005281924A JP 2005281924 A JP2005281924 A JP 2005281924A JP 2004100404 A JP2004100404 A JP 2004100404A JP 2004100404 A JP2004100404 A JP 2004100404A JP 2005281924 A JP2005281924 A JP 2005281924A
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Prior art keywords
resin
nonwoven fabric
sheath
core
yarn
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JP2004100404A
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JP4459680B2 (en
Inventor
Toshiyuki Ogata
敏之 尾形
Arata Kasai
新 河西
Hirofumi Yashiro
弘文 矢代
Akio Ota
明夫 太田
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Nitto Boseki Co Ltd
Ube Exsymo Co Ltd
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Nitto Boseki Co Ltd
Ube Nitto Kasei Co Ltd
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Priority to JP2004100404A priority Critical patent/JP4459680B2/en
Priority to CNB2005800063264A priority patent/CN100529225C/en
Priority to CA 2561911 priority patent/CA2561911A1/en
Priority to EP05727361A priority patent/EP1739220A4/en
Priority to US10/599,400 priority patent/US20080045109A1/en
Priority to PCT/JP2005/005874 priority patent/WO2005095701A1/en
Publication of JP2005281924A publication Critical patent/JP2005281924A/en
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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641Sheath-core multicomponent strand or fiber material

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Laminated Bodies (AREA)

Abstract

【課題】本発明は、柔軟性、追随性に優れ、かつ使用用途や必要とする特性に応じて、強度等を調整させることも可能な不織布の製造方法及び不織布を提供すること。
【解決手段】繊維状の芯部樹脂がこれより20℃以上融点の低い鞘部樹脂で囲繞された芯鞘構造を有する樹脂単繊維を複数本集束し、鞘部樹脂を融合させてなる複合糸を、経方向、斜方向及び逆斜方向の少なくとも3方向に積層する積層工程と、積層した繊維束同士を芯部樹脂の融点より低く、且つ鞘部樹脂の融点より高い温度で加熱して接着する接着工程と、を備える構成を採る。
【選択図】図1
The present invention provides a method for producing a nonwoven fabric and a nonwoven fabric that are excellent in flexibility and followability, and that can be adjusted in strength and the like according to the intended use and required properties.
A composite yarn obtained by bundling a plurality of resin single fibers having a core-sheath structure in which a fibrous core resin is surrounded by a sheath resin having a melting point of 20 ° C. or more lower than that, and fusing the sheath resin. Are laminated in at least three directions of warp direction, oblique direction and reverse oblique direction, and the laminated fiber bundles are heated and bonded at a temperature lower than the melting point of the core resin and higher than the melting point of the sheath resin. And a bonding step.
[Selection] Figure 1

Description

本発明は、連続繊維糸を積層してなる不織布の製造方法及び連続繊維糸を積層してなる不織布に関する。   The present invention relates to a method for producing a nonwoven fabric obtained by laminating continuous fiber yarns and a nonwoven fabric obtained by laminating continuous fiber yarns.

コンクリート剥落防止材等の産業資材として、ガラス繊維、炭素繊維、アラミド繊維、ビニロン繊維などの織物、編物のほか、各種の組布(連続繊維不織布)が一般に用いられている。組布には、経方向、斜方向及び逆斜方向に積層した三軸組布や、経方向、緯方向、斜方向及び逆斜方向に積層した四軸組布がある。   As industrial materials such as concrete peeling prevention materials, woven fabrics and knitted fabrics such as glass fibers, carbon fibers, aramid fibers, and vinylon fibers, and various braided fabrics (continuous fiber nonwoven fabrics) are generally used. As the braided fabric, there are a triaxial braided fabric laminated in the warp direction, the oblique direction, and the reverse oblique direction, and a four-axis assembled fabric laminated in the warp direction, the weft direction, the oblique direction, and the reverse oblique direction.

この組布の製造方法としては、例えば、ビニロン繊維等を所定の方向に引き揃え、ホットメルト接着剤やエマルジョン接着剤で繊維同士を接着させる製造方法が知られている。また、熱可塑性樹脂により被覆された強化繊維(ガラス繊維、炭素繊維、アルミナ繊維、アラミド繊維等)を引き揃えそれらを融着させる製造方法(例えば、特許文献1参照)や、強化繊維の表面上に熱可塑性樹脂を付着させて接着させる製造方法(例えば、特許文献2参照)も公知である。更に、芯部にポリエステル系重合体を、鞘部に芯部のポリエステル系重合体よりも低い融点を有するポリエステル系重合体の芯鞘構造糸を用いて製編織したメッシュシートも知られている(例えば、特許文献3参照)。
特開平11−20059号公報 WO00/21742号公報 特開2003−301346号公報
As a method of manufacturing this braided fabric, for example, a manufacturing method is known in which vinylon fibers are aligned in a predetermined direction and the fibers are bonded to each other with a hot melt adhesive or an emulsion adhesive. Further, a manufacturing method (for example, see Patent Document 1) in which reinforcing fibers (glass fiber, carbon fiber, alumina fiber, aramid fiber, etc.) coated with a thermoplastic resin are arranged and fused, or on the surface of the reinforcing fiber Also known is a production method (for example, see Patent Document 2) in which a thermoplastic resin is adhered to and adhered to the substrate. Furthermore, a mesh sheet knitted and woven using a polyester polymer in the core and a polyester polymer core-sheath structure yarn having a melting point lower than that of the polyester polymer in the core is also known ( For example, see Patent Document 3).
Japanese Patent Laid-Open No. 11-20059 WO00 / 21742 JP 2003-301346 A

しかし、ビニロン繊維を組んだ後、ホットメルト接着剤やエマルジョン接着剤で接着させる製造方法では、接着剤が必要であるためコスト高になり、不要な箇所にも接着剤が付着するため、不織布製造工程の作業環境に劣る問題がある。   However, the manufacturing method in which vinylon fibers are assembled and then bonded with a hot melt adhesive or emulsion adhesive increases the cost because an adhesive is required, and the adhesive also adheres to unnecessary parts, so the nonwoven fabric is manufactured. There is a problem inferior to the working environment of the process.

また、熱可塑性樹脂を用いて強化繊維を融着させる方法では、強化繊維を熱可塑性樹脂で完全に被覆することが困難であるため接着力が十分でなく、その結果、コンクリート剥落防止等の特に長期間にわたる用途に適用する場合、耐久性が十分ではない。   Further, in the method of fusing reinforcing fibers using a thermoplastic resin, it is difficult to completely cover the reinforcing fibers with the thermoplastic resin, so the adhesive force is not sufficient, and as a result, concrete peeling prevention etc. When applied to long-term use, the durability is not sufficient.

一方、ポリエステル系重合体の芯鞘構造糸を用いて製編織したメッシュシートにおいては、組布のように繊維間の空隙を大きくすることができないのでコンクリート剥落防止材等として適用することが困難であったり、またメッシュ体の製造に手間がかかり、コスト高になる問題がある。   On the other hand, in a mesh sheet knitted and woven using a polyester-sheath core-sheath structure yarn, it is difficult to apply as a concrete exfoliation preventing material, etc. In addition, there is a problem that it takes time to manufacture the mesh body and increases the cost.

更に、上記の開示例の組布及びメッシュシートはいずれも柔軟性や屈曲性に劣り追随性が十分ではない。このような組布及びメッシュシートであるとコンクリート剥落防止等の産業資材の分野では汎用性が劣ることとなるため、その改善が強く望まれている。   Furthermore, the braided fabric and the mesh sheet of the above disclosed example are both inferior in flexibility and flexibility and not sufficiently followable. Since such a braided fabric and mesh sheet are inferior in versatility in the field of industrial materials such as prevention of concrete peeling, improvement thereof is strongly desired.

そこで、本発明は優れた柔軟性および屈曲性を有し追随性に優れ、且つ使用用途や必要とする特性に応じて強度や柔軟性を調整することも可能な連続繊維からなる不織布の製造方法を提供することを目的とする。本発明はまたこの製造方法により得られる連続繊維からなる不織布を提供することを目的とする。   Therefore, the present invention provides a method for producing a nonwoven fabric comprising continuous fibers, which has excellent flexibility and flexibility, excellent followability, and whose strength and flexibility can be adjusted according to the intended use and required properties. The purpose is to provide. Another object of the present invention is to provide a nonwoven fabric composed of continuous fibers obtained by this production method.

上記目的を達成するため、本発明の不織布の製造方法は、繊維状の芯部樹脂がこれより20℃以上融点の低い鞘部樹脂で囲繞された芯鞘構造を有する樹脂単繊維を複数本集束し、この鞘部樹脂を融合させてなる複合糸を経方向、斜方向及び逆斜方向の少なくとも3方向に積層する積層工程と、積層した複合糸同士を芯部樹脂の融点より低く、且つ鞘部樹脂の融点より高い温度で加熱して接着する接着工程と、を備えることを特徴とする。   In order to achieve the above object, the method for producing a nonwoven fabric according to the present invention focuses a plurality of resin single fibers having a core-sheath structure in which a fibrous core resin is surrounded by a sheath resin having a melting point lower than 20 ° C. A laminating step of laminating the composite yarn obtained by fusing the sheath resin in at least three directions of the warp direction, the oblique direction, and the reverse oblique direction; and the laminated composite yarns are lower than the melting point of the core resin, and the sheath An adhesion step of heating and bonding at a temperature higher than the melting point of the partial resin.

本発明の不織布の製造方法における複合糸は、鞘部樹脂を融合させているため、優れた柔軟性、強度を有しており、更に樹脂単繊維がばらけることがないので、不織布製造においてトラブルが少なく、柔軟性、強度の優れた不織布を製造することができる。また、芯鞘構造の鞘部樹脂が芯部樹脂より20℃以上融点が低いため、本発明の不織布の製造方法において複合糸を各方向に積層した後、芯部樹脂の融点より低く鞘部樹脂の融点より高い温度で加熱した場合、芯部樹脂を溶融させず鞘部樹脂のみを溶融させ、複合糸同士を接着させることが可能となる。すなわち、ホットメルト樹脂や熱可塑性樹脂等の接着剤を使用しなくても本発明の不織布を製造することができる。また、融点の差が20℃以上であることから、鞘部樹脂を溶融させても芯部樹脂は溶融し難くなり、芯部樹脂は繊維状の形態を維持しているので、不織布の製造時に複合糸が変形することを防止することが可能となる。すなわち、芯鞘構造を有しない樹脂単繊維を用いたときに生じやすい複合糸の変形や切断を防止することができるため、製造上のトラブルが更に少なくなる。   The composite yarn in the method for producing a nonwoven fabric of the present invention has excellent flexibility and strength because the sheath resin is fused, and further, the resin monofilament does not come apart. Therefore, it is possible to produce a non-woven fabric excellent in flexibility and strength. Moreover, since the sheath resin of the core-sheath structure has a melting point of 20 ° C. or more lower than that of the core resin, after laminating the composite yarn in each direction in the method for producing a nonwoven fabric of the present invention, the sheath resin is lower than the melting point of the core resin. When heated at a temperature higher than the melting point, the core resin is not melted, only the sheath resin is melted, and the composite yarns can be bonded to each other. That is, the nonwoven fabric of the present invention can be produced without using an adhesive such as a hot melt resin or a thermoplastic resin. In addition, since the difference in melting point is 20 ° C. or more, the core resin becomes difficult to melt even when the sheath resin is melted, and the core resin maintains a fibrous form. It is possible to prevent the composite yarn from being deformed. That is, since it is possible to prevent deformation and cutting of the composite yarn that is likely to occur when a resin single fiber having no core-sheath structure is used, troubles in manufacturing are further reduced.

また、経方向、斜方向及び逆斜方向の少なくとも3方向に複合糸を積層するため、方向性を問わず強度に優れる不織布を製造することができる。   Moreover, since the composite yarn is laminated in at least three directions of warp direction, oblique direction and reverse oblique direction, a nonwoven fabric having excellent strength can be produced regardless of directionality.

更に、本発明の不織布の製造方法における複合糸は、10〜500本の樹脂単繊維からなるものであり、複合糸において、芯部樹脂が繊度1〜70dtexの繊維状の島部(島部樹脂)を形成し、融合した鞘部樹脂は海部(海部樹脂)を形成していることが好ましい。このような複合糸は、繊維強化熱可塑性樹脂の形態なので、長手(繊維軸)方向に強度性、剛性を有しており、このような複合糸を用いることにより不織布の柔軟性、強度を更に向上させることができる。また、島部樹脂の断面径や集束本数を調整することにより、強度や柔軟性を好適にすることができ、追随性も一層向上させることができる。   Furthermore, the composite yarn in the method for producing a nonwoven fabric of the present invention is composed of 10 to 500 resin single fibers, and in the composite yarn, a fibrous island portion (island portion resin) having a core resin with a fineness of 1 to 70 dtex. ) And the fused sheath resin preferably forms a sea part (sea part resin). Since such a composite yarn is in the form of a fiber-reinforced thermoplastic resin, it has strength and rigidity in the longitudinal (fiber axis) direction. By using such a composite yarn, the flexibility and strength of the nonwoven fabric can be further increased. Can be improved. In addition, by adjusting the cross-sectional diameter and the number of focused portions of the island resin, the strength and flexibility can be made suitable, and the followability can be further improved.

また、本発明の不織布の製造方法では、芯鞘構造の樹脂単繊維における芯部樹脂及び鞘部樹脂はポリオレフィンであることが好ましい。芯部樹脂をポリオレフィンとすることにより柔軟性及び作業性が優れるようになる。また、芯部樹脂及び鞘部樹脂が共にポリオレフィンである場合は芯部樹脂及び鞘部樹脂の親和性が優れるため、鞘部樹脂であるポリオレフィンが溶融したとしても、芯部樹脂であるポリオレフィンから分離することなく芯部が補強繊維、鞘部がマトリックス樹脂の形態の複合糸構造を維持することができる。また、ポリオレフィンは無極性であることから酸や塩基にも強く、耐久性に優れる不織布を製造することができる。   Moreover, in the manufacturing method of the nonwoven fabric of this invention, it is preferable that the core part resin and sheath part resin in the resin single fiber of a core sheath structure are polyolefin. By making the core resin a polyolefin, flexibility and workability are improved. Also, when both the core resin and the sheath resin are polyolefin, the affinity of the core resin and the sheath resin is excellent, so even if the polyolefin that is the sheath resin melts, it is separated from the polyolefin that is the core resin. Without this, a composite yarn structure in which the core portion is in the form of reinforcing fibers and the sheath portion is in the form of a matrix resin can be maintained. In addition, since polyolefin is nonpolar, it is resistant to acids and bases, and can produce a nonwoven fabric excellent in durability.

更に、上記の芯部樹脂はポリプロピレンであることが好ましく、鞘部樹脂は融点120℃以下のポリエチレンであることが好ましい。このような構成の不織布は、複合糸の特性と相俟って、特に優れた柔軟性及び屈曲性を有し追随性に優れる。すなわち、従来の組布では折れ曲がった箇所を被覆するように用いた場合、柔軟性および屈曲性が劣るため組布の弾力性で跳ね返ってしまい角部の被覆が困難であったのに対して、本発明の不織布は容易に折れ曲がり、対象物に追随し密着した施工を行うことができる。   Further, the core resin is preferably polypropylene, and the sheath resin is preferably polyethylene having a melting point of 120 ° C. or lower. The nonwoven fabric having such a configuration, in combination with the characteristics of the composite yarn, has particularly excellent flexibility and flexibility and excellent followability. That is, when used to cover a bent portion in a conventional braid, it was difficult to cover the corners because it was rebounded by the elasticity of the braid because of its poor flexibility and flexibility. The nonwoven fabric of the present invention can be bent easily, and can be applied in close contact with the object.

特に、芯部樹脂がポリプロピレンであると、融点が比較的高いことから、熱、或いは酸や塩基によって分離したり分解したりすることを防止することができる。したがって、長期間使用しても不織布の形態を維持することができる。更に、ポリプロピレンは熱可塑性樹脂であるため、リサイクルすることも可能となり環境にもやさしい。   In particular, since the melting point of the core resin is relatively high, it can be prevented from being separated or decomposed by heat, acid or base. Therefore, the form of the nonwoven fabric can be maintained even when used for a long time. Furthermore, since polypropylene is a thermoplastic resin, it can be recycled and is environmentally friendly.

また、鞘部樹脂がポリエチレンであると融点が比較的低いことから、容易に溶融させることができ、特に融点120℃以下であると加工効率が飛躍的に向上し、エネルギーロスも少なくなる。   Moreover, since melting | fusing point is comparatively low when sheath resin is polyethylene, it can melt | dissolve easily, and when it is especially melting | fusing point 120 degrees C or less, processing efficiency will improve dramatically and energy loss will also decrease.

また、本発明の不織布は、繊度1〜70dtexの繊維状の島部樹脂10〜500本が繊維状の海部樹脂中に配された複合糸(繊維状の海部樹脂の長手方向に沿うように繊維状の島部樹脂が配されていることが好ましい)を、経方向、斜方向及び逆斜方向の少なくとも3方向に積層し、海部樹脂を溶融させて積層した複合糸同士を接着した不織布であって、海部樹脂が島部樹脂より20℃以上低い融点を有することを特徴とする不織布である。このような複合糸は柔軟性に優れるため不織布の製造上でのトラブルが少なく、且つ柔軟性、強度に優れた不織布を得ることができる。   In addition, the nonwoven fabric of the present invention is a composite yarn in which 10 to 500 fibrous island resins having a fineness of 1 to 70 dtex are arranged in a fibrous sea resin (fibers so as to be along the longitudinal direction of the fibrous sea resin) Is preferably a non-woven fabric in which composite yarns are laminated to each other by melting sea part resin and laminating them in at least three directions of warp, oblique and reverse oblique directions. The sea part resin is a non-woven fabric characterized by having a melting point lower by 20 ° C. or more than the island part resin. Since such a composite yarn is excellent in flexibility, there are few troubles in the production of the nonwoven fabric, and a nonwoven fabric excellent in flexibility and strength can be obtained.

本発明の不織布における複合糸の製造方法は、下記いずれかの方法により得ることができる。すなわち、
(1)芯鞘構造の樹脂単繊維を集束し、芯部樹脂の融点より低く鞘部樹脂の融点より高い温度で延伸しつつ鞘部樹脂を溶融せしめ鞘部樹脂同士を融合し海部樹脂(マトリックス)を構成させ、芯部樹脂を島部樹脂(補強繊維)とする海島構造の複合糸とする方法。
(2)延伸された芯鞘構造の繊維を引き揃えた状態で鞘部の融点より高く、芯部の融点より低い温度で加熱しつつ、所定径のダイスに通して鞘部同士を熱融着する方法。
(3)島部樹脂と、この島部樹脂より20℃以上融点の低い海部樹脂からなる海島構造を有する未延伸糸を延伸させる方法。
より優れた柔軟性および強度を有する複合糸を得るためには、上述の(1)または(2)の方法が好ましく、特に(1)の方法が好ましい。
The method for producing a composite yarn in the nonwoven fabric of the present invention can be obtained by any of the following methods. That is,
(1) A core-sheath resin single fiber is converged and stretched at a temperature lower than the melting point of the core resin and higher than the melting point of the sheath resin. ) And a composite yarn having a sea-island structure in which the core resin is an island resin (reinforcing fiber).
(2) Heat-sealing the sheath parts through a die of a predetermined diameter while heating at a temperature higher than the melting point of the sheath part and lower than the melting point of the core part in a state where the fibers of the stretched core-sheath structure are aligned. how to.
(3) A method of stretching an unstretched yarn having an island-island structure composed of an island resin and a marine resin having a melting point of 20 ° C. or more lower than that of the island resin.
In order to obtain a composite yarn having more excellent flexibility and strength, the method (1) or (2) described above is preferable, and the method (1) is particularly preferable.

また、本発明の不織布における海島構造の複合糸は、海部樹脂および島部樹脂はポリオレフィンであることが好ましく、さらに、海部樹脂はポリプロピレンであり島部樹脂は融点120℃以下のポリエチレンであることが好ましい。   In the sea-island structure composite yarn of the nonwoven fabric of the present invention, the sea part resin and the island part resin are preferably polyolefin, and the sea part resin is polypropylene and the island part resin is polyethylene having a melting point of 120 ° C. or lower. preferable.

さらに、本発明の不織布においては、複合糸における島部樹脂と海部樹脂の質量比が、20:80〜80:20であることが好ましい。このような質量比にすることにより、強度及び柔軟性を適宜調整することができる。   Furthermore, in the nonwoven fabric of this invention, it is preferable that mass ratio of island part resin and sea part resin in a composite yarn is 20: 80-80: 20. By setting it as such a mass ratio, intensity | strength and a softness | flexibility can be adjusted suitably.

本発明の不織布の製造方法によれば、柔軟性及び追随性に優れ、且つ使用用途や必要とする特性に応じて強度や柔軟性を調整することも可能な不織布を製造することができる。また、この製造方法で得られる不織布は、コンクリート剥落防止材、河川敷の保護網、養殖貝の流出防止網、害獣対策のためのネット、フィルターのケーシング材などに有用である。   According to the method for producing a nonwoven fabric of the present invention, it is possible to produce a nonwoven fabric that is excellent in flexibility and followability and whose strength and flexibility can be adjusted according to the intended use and required properties. In addition, the nonwoven fabric obtained by this production method is useful as a concrete flaking prevention material, a riverbed protection net, a cultured shell outflow prevention net, a net for pest control, a filter casing material, and the like.

以下、図面を参照して本発明の好適な実施形態について詳細に説明する。図1は、実施形態に係る不織布を示す平面図である。   DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings. Drawing 1 is a top view showing the nonwoven fabric concerning an embodiment.

図1に示す不織布10は、経方向に複数並列した経糸11と、経糸11と斜交するように複数並列した斜交糸12と、経糸11及び斜交糸12に斜交するように複数並列した逆斜交糸13と、から構成されている。ここで、経糸11、斜交糸12及び逆斜交糸13はいずれも複合糸であり、引き揃えられた方向が異なる以外は同一である。また、経糸11、斜交糸12及び逆斜交糸13はいずれも等間隔で配列され、経糸11及び斜交糸12の接面は逆斜交糸13上に位置している。   The nonwoven fabric 10 shown in FIG. 1 includes a plurality of warp yarns 11 arranged in parallel in the warp direction, a plurality of oblique yarns 12 arranged in parallel so as to obliquely intersect with the warp yarns 11, and a plurality of parallel yarns arranged obliquely in the warp yarns 11 and the oblique yarns 12. And the reverse oblique yarn 13. Here, the warp yarn 11, the oblique yarn 12, and the reverse oblique yarn 13 are all composite yarns, and are the same except that the aligned directions are different. The warp yarn 11, the oblique yarn 12 and the reverse oblique yarn 13 are all arranged at equal intervals, and the contact surfaces of the warp yarn 11 and the oblique yarn 12 are positioned on the reverse oblique yarn 13.

図2は、経糸11、斜交糸12及び逆斜交糸13が交差する部分(図1におけるPの領域)を拡大した斜視図である。図2に示すように実施形態に係る経糸11、斜交糸12及び逆斜交糸13は楕円状の断面形状を有している。経糸11は斜交糸12と接面Hにおいて接着されており、逆斜交糸13は接面Hと反対の面で斜交糸12と接着されている。また、経糸11と斜交糸12との接面H及び斜交糸12と逆斜交糸13との接面は、鞘部樹脂が溶融して接着している。   FIG. 2 is an enlarged perspective view of a portion where the warp yarn 11, the oblique yarn 12, and the reverse oblique yarn 13 intersect (P area in FIG. 1). As shown in FIG. 2, the warp yarn 11, the oblique yarn 12, and the reverse oblique yarn 13 according to the embodiment have an elliptical cross-sectional shape. The warp yarn 11 is bonded to the oblique yarn 12 on the contact surface H, and the reverse oblique yarn 13 is bonded to the oblique yarn 12 on the surface opposite to the contact surface H. In addition, the sheath resin melts and adheres to the contact surface H between the warp yarn 11 and the oblique yarn 12 and the contact surface between the oblique yarn 12 and the reverse oblique yarn 13.

図3(a)は、樹脂単繊維が集束したもの(以下「樹脂単繊維束」という。)を示す斜視図である。図3(a)に示す樹脂単繊維束20aは、例えば、樹脂単繊維を未延伸状態で集束して得られる。すなわち、樹脂単繊維束20aは、芯部樹脂21aと鞘部樹脂22aからなる芯鞘構造を有する樹脂単繊維23aを複数本集束してなるものである。   FIG. 3A is a perspective view showing a bundle of resin single fibers (hereinafter referred to as “resin single fiber bundle”). The resin single fiber bundle 20a shown in FIG. 3A is obtained by, for example, converging resin single fibers in an unstretched state. That is, the resin single fiber bundle 20a is formed by bundling a plurality of resin single fibers 23a having a core-sheath structure including a core resin 21a and a sheath resin 22a.

図3(b)は、本発明における複合糸を示す斜視図である。複合糸20bは、例えば、図3(a)に示す芯鞘構造の樹脂単繊維23aを複数本集束した未延伸の樹脂単繊維束20aを延伸しつつ鞘部樹脂を溶融し、鞘部樹脂同士を融合して、断面形状を略楕円状に整えて海島構造を形成させたものである。   FIG.3 (b) is a perspective view which shows the composite yarn in this invention. For example, the composite yarn 20b melts the sheath resin while stretching the unstretched resin single fiber bundle 20a in which a plurality of resin single fibers 23a having a core-sheath structure shown in FIG. And the sea-island structure is formed by adjusting the cross-sectional shape to a substantially elliptical shape.

すなわち、複合糸20bにおいては、図3(b)に示すように、芯部樹脂21aが島部樹脂21bを形成し、鞘部樹脂22aが融合して海部樹脂22bを形成する。その結果、全体として海島構造が形成される。このようにして得られた複合糸20bは強度、柔軟性の点から不織布10を得るための複合糸として最も適している。   That is, in the composite yarn 20b, as shown in FIG. 3B, the core resin 21a forms the island resin 21b, and the sheath resin 22a fuses to form the sea resin 22b. As a result, a sea-island structure is formed as a whole. The composite yarn 20b thus obtained is most suitable as a composite yarn for obtaining the nonwoven fabric 10 in terms of strength and flexibility.

図4(a)(b)は経糸11と斜交糸12との接面と逆斜交糸13の位置関係を示す平面図である。図4(a)では、経糸11と斜交糸12の接面が逆斜交糸13上にあり、図1に示す不織布10はこのような位置関係を有している。これに対して、図4(b)では、経糸11及び斜交糸12の接面が逆斜交糸13上に存在せず、経糸11と斜交糸12、経糸11と逆斜交糸13、斜交糸12と逆斜交糸13とがそれぞれ接着される。本発明に係る不織布は、少なくとも一部がこのような位置関係を有するものであってもよい。   4A and 4B are plan views showing the positional relationship between the contact surface of the warp 11 and the oblique yarn 12 and the reverse oblique yarn 13. In Fig.4 (a), the contact surface of the warp 11 and the diagonal thread 12 exists on the reverse diagonal thread 13, and the nonwoven fabric 10 shown in FIG. 1 has such a positional relationship. On the other hand, in FIG. 4B, the contact surfaces of the warp 11 and the oblique yarn 12 do not exist on the reverse oblique yarn 13, but the warp 11 and the oblique yarn 12, and the warp 11 and the reverse oblique yarn 13 are present. The oblique yarn 12 and the reverse oblique yarn 13 are bonded to each other. At least a part of the nonwoven fabric according to the present invention may have such a positional relationship.

不織布10は経方向、斜方向及び逆斜方向に繊維束が積層されているため、方向性を問わず強度に優れる。また、不織布10は、図1に示すように、経糸11、斜交糸12及び逆斜交糸13の配列がいずれも等間隔であるため、不織布の強度のばらつきがなくバランスに優れる。更に、各繊維束が交差することで正三角形をなすために、不織布10は意匠性にも優れる。   Since the nonwoven fabric 10 has fiber bundles laminated in the warp direction, the oblique direction, and the reverse oblique direction, it is excellent in strength regardless of the directionality. Further, as shown in FIG. 1, the nonwoven fabric 10 is excellent in balance because there is no variation in strength of the nonwoven fabric because the warp yarns 11, the oblique yarns 12, and the reverse oblique yarns 13 are all arranged at equal intervals. Furthermore, since the fiber bundles intersect to form a regular triangle, the nonwoven fabric 10 is also excellent in design.

なお、上記の各繊維束間は必ずしも等間隔である必要はない。不織布10は、経糸11間、斜交糸12間、或いは逆斜交糸13間の間隔を調整することにより所望の柔軟性や強度を得ることができ、各繊維束間の空隙の大きさを調整することもできる。したがって、使用態様や目的にしたがい必要とする特性を付与することができる。   Note that the above-mentioned fiber bundles do not necessarily have an equal interval. The nonwoven fabric 10 can obtain desired flexibility and strength by adjusting the spacing between the warp yarns 11, between the oblique yarns 12, or between the inverted oblique yarns 13. It can also be adjusted. Therefore, the required characteristics can be imparted according to the usage mode and purpose.

このように不織布10は強度及び追随性に優れるため産業資材分野において好適に使用できる。特に、各繊維束間の空隙を調整することができることから、例えば、コンクリート剥落防止材として使用する場合、繊維束間の空隙がある程度大きいと、コンクリートとの一体性に優れ高い剥落防止性能を発揮することができる。   Thus, since the nonwoven fabric 10 is excellent in intensity | strength and followability, it can be used conveniently in the industrial material field | area. In particular, since the gaps between the fiber bundles can be adjusted, for example, when used as a concrete peeling prevention material, if the gaps between the fiber bundles are large to some extent, they are excellent in integrity with concrete and exhibit high peeling prevention performance. can do.

また、不織布10は製造のためのホットメルト接着剤や熱可塑性樹脂等の接着剤は不要であるため、ホットメルト接着剤や熱可塑性樹脂等を付与する工程を省くことができ加工速度を速めることができる。更に、不織布10は経糸11、斜交糸12及び逆斜交糸13を積層し加熱することによって接着できるため、比較的容易に製造することができる。すなわち、大量生産が容易であり生産性に優れる。   Moreover, since the nonwoven fabric 10 does not require an adhesive such as a hot melt adhesive or a thermoplastic resin for manufacturing, the step of applying the hot melt adhesive or the thermoplastic resin can be omitted, and the processing speed can be increased. Can do. Furthermore, since the nonwoven fabric 10 can be bonded by laminating the warp yarn 11, the oblique yarn 12, and the reverse oblique yarn 13 and heating them, it can be manufactured relatively easily. That is, mass production is easy and productivity is excellent.

また、図3(b)に示すように、複合糸20bは海島構造を有するため、不織布10を製造する時に海部樹脂22bが溶融し、隣接する複合糸20bの海部樹脂22bと融合し接着する。したがって不織布10は全体として高い強度を示す。   3B, since the composite yarn 20b has a sea-island structure, the sea resin 22b is melted when the nonwoven fabric 10 is manufactured, and is fused and bonded to the sea resin 22b of the adjacent composite yarn 20b. Therefore, the nonwoven fabric 10 exhibits high strength as a whole.

芯部樹脂21aは鞘部樹脂22aより20℃以上高い融点を有する必要がある。融点の差を20℃以上とすると、鞘部樹脂を溶融させても芯部樹脂は溶融し難くなり、芯部繊維の強度を保持しつつ複合糸の形態を維持することができる。したがって、融点の差は大きいほうが好ましく40℃以上であるのが更に好ましい。   The core resin 21a needs to have a melting point 20 ° C. higher than the sheath resin 22a. When the difference in melting point is 20 ° C. or more, the core resin is difficult to melt even when the sheath resin is melted, and the form of the composite yarn can be maintained while maintaining the strength of the core fiber. Accordingly, the difference in melting point is preferably larger, and more preferably 40 ° C. or higher.

本実施形態では芯部樹脂21aはポリプロピレンからなり、鞘部樹脂22aはポリエチレンからなる。鞘部樹脂22aをポリエチレンとすると、ポリエチレンは熱可塑性であって且つ比較的低融点であるため、加熱する際には効率良く溶融させ接着させることができる。また、芯部樹脂21aをポリプロピレンとすると、ポリプロピレンの融点は比較的高いため長期間用いても熱安定性に優れ、また、無極性であることから、酸や塩基による分離や分解がし難いため耐久性に優れる。更に、使用後は溶融し再成型することによって容易にリサイクルすることができる。したがって、産業廃棄物とはならず安全性にも優れるため環境にやさしい。   In the present embodiment, the core resin 21a is made of polypropylene, and the sheath resin 22a is made of polyethylene. When the sheath resin 22a is made of polyethylene, since polyethylene is thermoplastic and has a relatively low melting point, it can be efficiently melted and bonded when heated. Also, when the core resin 21a is polypropylene, the melting point of polypropylene is relatively high, so that it has excellent thermal stability even when used for a long period of time, and since it is nonpolar, it is difficult to separate or decompose by acid or base. Excellent durability. Furthermore, after use, it can be easily recycled by melting and remolding. Therefore, it is environmentally friendly because it is not industrial waste and has excellent safety.

また、ポリプロピレン及びポリエチレンを用いて上記構造とすることで、各複合糸間の空隙を狭くしたり、芯鞘構造を有する樹脂単繊維の本数を増やした複合糸を用いたりして不織布の強度を高めた場合であっても、特異的に柔軟性に優れ、また、折れ曲がりやすい。したがって、このような構成の不織布は、折れ曲がった箇所や湾曲した箇所に被覆するように用いた場合であっても、対象物に密着させて被覆することができる。   In addition, by using polypropylene and polyethylene as the above structure, the gap between each composite yarn is narrowed, or the composite yarn with an increased number of single resin fibers having a core-sheath structure is used to increase the strength of the nonwoven fabric. Even when it is raised, it has excellent flexibility and is easy to bend. Therefore, even when the nonwoven fabric having such a configuration is used so as to cover a bent portion or a curved portion, it can be coated while being in close contact with an object.

本発明において用いられるポリエチレンは低密度ポリエチレンであることが好ましく、融点が120℃以下であることが更に好ましい。低密度ポリエチレンであると融点が低いため特に低温で接着を行うことができ加工効率も飛躍的に向上する。   The polyethylene used in the present invention is preferably low-density polyethylene, and more preferably has a melting point of 120 ° C. or lower. Since low melting polyethylene has a low melting point, it can be bonded particularly at a low temperature, and the processing efficiency is also greatly improved.

島部樹脂21bであるポリプロピレンの繊度は、1〜70dtexであることが好ましく、さらに好ましくは繊度は2〜50dtexである。特に柔軟性を求められるときは30dtex以下が好ましい。繊度が、1dtex未満であると、島部樹脂21bが細くなりすぎるため、形態を維持することが困難となり、熱接着後の物性が低下しやすい。一方、繊度が70dtexを超えると、樹脂単繊維23a自体が太くなりすぎるため、柔軟性や屈曲性が損なわれる虞がある。   The fineness of the polypropylene that is the island resin 21b is preferably 1 to 70 dtex, more preferably 2 to 50 dtex. Especially when flexibility is required, it is preferably 30 dtex or less. If the fineness is less than 1 dtex, the island resin 21b becomes too thin, so that it is difficult to maintain the form, and the physical properties after heat bonding are likely to be lowered. On the other hand, if the fineness exceeds 70 dtex, the resin single fiber 23a itself becomes too thick, and there is a possibility that the flexibility and the flexibility are impaired.

また、複合糸は樹脂単繊維23aを複数本集束しつつ延伸して製造され得るが、この場合、集束する本数は10〜500本が好ましい。10本未満であると、樹脂単繊維23aが太くなり紡糸性が悪化する虞があり、500本を超えると、紡糸ノズル密度が増加し、樹脂単繊維23aも細くなるため、紡糸性、延伸性が悪化する虞がある。更に好ましくは、100〜300本である。   The composite yarn can be produced by drawing a plurality of resin single fibers 23a while being bundled. In this case, the number of bundles is preferably 10 to 500. If the number is less than 10, the resin single fiber 23a may become thick and the spinnability may be deteriorated. If the number exceeds 500, the spinning nozzle density increases and the resin single fiber 23a also becomes thin. May get worse. More preferably, it is 100-300.

また、複合糸20bの繊度は100〜5000dtexが好ましい。100dtex未満であると、目的とする物性が得られ難くなり、5000dtexを超えると柔軟性や追随性が損なわれる虞がある。更に好ましくは、500〜3000dtexである   Further, the fineness of the composite yarn 20b is preferably 100 to 5000 dtex. If it is less than 100 dtex, it is difficult to obtain desired physical properties, and if it exceeds 5000 dtex, flexibility and followability may be impaired. More preferably, it is 500 to 3000 dtex.

本発明に係る不織布は島部樹脂21bと海部樹脂22bの質量比が20:80〜80:20であることが好ましい。島部樹脂21bの海部樹脂22bに対する質量比が割合で20%未満であると、目的とする物性が得られ難くなる虞があり、島部樹脂21bの海部樹脂22bに対する質量比が割合で80%を超えると、熱接着強度が低下する虞がある。更に好ましくは、40:60〜70:30である。   In the nonwoven fabric according to the present invention, the mass ratio of the island resin 21b and the sea resin 22b is preferably 20:80 to 80:20. If the mass ratio of the island resin 21b to the sea resin 22b is less than 20%, the target physical properties may be difficult to obtain, and the mass ratio of the island resin 21b to the sea resin 22b may be 80%. If it exceeds, the thermal bond strength may be reduced. More preferably, it is 40: 60-70: 30.

不織布10は不織布製造装置を用いて製造できる。図5(a)は、不織布10を製造可能な製造装置の平面図であり、図5(b)は、その正面図である。   The nonwoven fabric 10 can be manufactured using a nonwoven fabric manufacturing apparatus. Fig.5 (a) is a top view of the manufacturing apparatus which can manufacture the nonwoven fabric 10, and FIG.5 (b) is the front view.

図5(a)(b)に示す不織布製造装置30は、断面形状が円形のドラム31と、トラバーサ34と、緯糸送り出し機構35と、を備えている。ドラム31は、y方向に平行な回転軸32を中心として図中の反時計回りに回転する。トラバーサ34は、ドラム31の側面に沿ってy方向に往復し、ドラム31に供給されている経糸群T1上に斜交糸群T3を形成する。緯糸送り出し機構35は、斜交糸群T3を形成するための緯糸群T2をトラバーサ34へ送り出している。   The nonwoven fabric manufacturing apparatus 30 shown in FIGS. 5A and 5B includes a drum 31 having a circular cross section, a traverser 34, and a weft feed mechanism 35. The drum 31 rotates counterclockwise in the figure around a rotation axis 32 parallel to the y direction. The traverser 34 reciprocates in the y direction along the side surface of the drum 31 to form an oblique yarn group T3 on the warp group T1 supplied to the drum 31. The weft sending mechanism 35 sends the weft group T2 for forming the oblique thread group T3 to the traverser 34.

不織布製造装置30を用いて不織布10を製造する場合、まず、経方向(図中のX方向)に経糸11が複数並列した経糸群T1は、円柱形をなすドラム31の側面に沿って、円周方向に巻き付くように供給される。ドラム31は、軸32を中心として回転可能に基台(図示せず)に支持され、基台に対して一定の速度で回転している。ドラム31の縁部の円周上には、糸掛具33a及びもう一方の縁部の円周上には、糸掛具33bが円柱側面から垂直に突出するように設けられ、円周を等分するように配置されている。トラバーサ34は、ドラム31の側面に沿って円弧状に設けられ、ドラム31の側面に沿ってY方向に往復動可能に支持されている。トラバーサ34は、緯糸送り出し機構35から送り出される緯糸群T2の各々を貫通させる貫通孔36を有している。緯糸群T2は、緯糸送り出し機構35から上記貫通孔36を介してドラム31に送られ、糸掛具33aと糸掛具33bとの間を交互に引っ掛けられながらドラム31の両縁部を往復し、ドラム31の側面上に送られる経糸群T1の上に、斜交糸12及び逆斜交糸13が複数並列した斜交糸群T3として張られていく。   When the nonwoven fabric 10 is manufactured using the nonwoven fabric manufacturing apparatus 30, first, the warp group T1 in which a plurality of warp yarns 11 are arranged in the warp direction (X direction in the figure) is circular along the side surface of the cylindrical drum 31. It is supplied so as to wind around in the circumferential direction. The drum 31 is supported by a base (not shown) so as to be rotatable about a shaft 32, and rotates at a constant speed with respect to the base. On the circumference of the edge of the drum 31, the thread hook 33a and on the circumference of the other edge are provided so that the thread hook 33b protrudes perpendicularly from the cylindrical side surface. Arranged to divide. The traverser 34 is provided in an arc shape along the side surface of the drum 31, and is supported so as to reciprocate in the Y direction along the side surface of the drum 31. The traverser 34 has a through hole 36 through which each weft group T2 fed from the weft feed mechanism 35 passes. The weft group T2 is fed from the weft feed mechanism 35 to the drum 31 through the through hole 36, and reciprocates between both edges of the drum 31 while being alternately hooked between the thread hook 33a and the thread hook 33b. On the warp group T1 sent on the side surface of the drum 31, a plurality of oblique yarns 12 and reverse oblique yarns 13 are stretched as an oblique yarn group T3 arranged in parallel.

このようにして、経糸群T1上に斜交して張られた斜交糸群T3によって不織布10が形成される。トラバーサ34の往復動ピッチはドラム31回転ピッチに対して所定の比になるように制御されている。トラバーサ34の往復動ピッチとドラム31の回転ピッチとの比は機械的に連動させて直接制御されてもよく、サーボモータで間接的に制御されてもよい。   In this way, the nonwoven fabric 10 is formed by the oblique yarn group T3 obliquely stretched on the warp yarn group T1. The reciprocating pitch of the traverser 34 is controlled to be a predetermined ratio with respect to the drum 31 rotation pitch. The ratio between the reciprocating pitch of the traverser 34 and the rotation pitch of the drum 31 may be directly controlled mechanically linked or indirectly controlled by a servo motor.

多岐にわたる産業資材の分野においては、より強度のある不織布を求められる場合がある。その場合は上述したように組布の密度を高めることによって、強度を高めることができる。すなわち、上記経方向(図中のX方向)に経糸11が複数並列した経糸群T1の経糸11の本数を増やしたり、ドラム31の縁部の円周上に設けられた糸掛具33a及び33bの間隔を狭めることによって、密度の高い不織布を提供することができる。   In a wide range of industrial materials, a stronger non-woven fabric may be required. In that case, the strength can be increased by increasing the density of the braid as described above. That is, the number of warps 11 of the warp group T1 in which a plurality of warps 11 are arranged in parallel in the warp direction (X direction in the figure) is increased, or the thread hooks 33a and 33b provided on the circumference of the edge of the drum 31. By narrowing the interval, a high density non-woven fabric can be provided.

本発明に係る不織布の製造方法においては、経方向、斜方向及び逆斜方向に引き揃えられた複合糸を加熱により接着させる。加熱温度は芯部樹脂の融点より低く、鞘部樹脂の融点より高い温度で行う。この温度で加熱処理を行うと芯鞘構造の芯部樹脂を溶融させずに鞘部樹脂のみを溶融させて接着することができ、不織布全体の強度を向上させることができる。鞘部樹脂の溶融のための加熱は加熱ローラなどによる接触加熱が好ましい。   In the method for producing a nonwoven fabric according to the present invention, composite yarns aligned in the warp direction, the oblique direction, and the reverse oblique direction are bonded by heating. The heating temperature is lower than the melting point of the core resin and higher than the melting point of the sheath resin. When heat treatment is performed at this temperature, the core resin having the core / sheath structure can be melted and bonded without melting the core resin, and the strength of the entire nonwoven fabric can be improved. The heating for melting the sheath resin is preferably contact heating with a heating roller or the like.

また、加熱処理に加え、シリンダー加圧、エアー加圧、自重による加圧などの加圧処理も行うのが好ましい。加圧処理を行うと複合糸の接面の面積が大きくなり、接面の接着力が強くなると同時に、不織布の厚みを調節することが出来る。
また、本発明に係る不織布は、加熱された状態で加圧を行うことが更に好ましい。加熱によって複合糸の海部樹脂が溶融され、他の複合糸の海部樹脂と接着するが、加熱された状態で加圧を行うと複合糸が押しつぶされ複合糸と他の複合糸との接面が更に大きくなる。したがって、加熱と同時に加圧をするとより強固な接着力を発揮することができる。なお、前述したドラム31で加圧接触することとすれば一度に加熱加圧処理を行うことが可能で作業性も良好となる。
In addition to the heat treatment, it is also preferable to perform a pressure treatment such as cylinder pressure, air pressure, or pressure due to its own weight. When the pressure treatment is performed, the area of the contact surface of the composite yarn is increased, the adhesive force of the contact surface is increased, and at the same time, the thickness of the nonwoven fabric can be adjusted.
The nonwoven fabric according to the present invention is more preferably pressed in a heated state. The sea part resin of the composite yarn is melted by heating and adheres to the sea part resin of other composite yarns. However, when pressure is applied in a heated state, the composite yarn is crushed and the contact surface between the composite yarn and the other composite yarns becomes It gets bigger. Therefore, when pressure is applied simultaneously with heating, a stronger adhesive force can be exhibited. In addition, if it press-contacts with the drum 31 mentioned above, a heat press process can be performed at once and workability | operativity will also become favorable.

以上、本発明に係る不織布の製造方法の実施形態について説明したが、本発明は必ずしも上述した実施形態に限定されるものではなく、種々の変形が可能である。   As mentioned above, although embodiment of the manufacturing method of the nonwoven fabric which concerns on this invention was described, this invention is not necessarily limited to embodiment mentioned above, A various deformation | transformation is possible.

例えば、樹脂単繊維束23aを複合糸20bとした後、複合糸に柔軟性を付与する目的で、捲縮や仮撚り技術を転用することも可能である。捲縮や仮撚り技術を転用することにより、繊維の柔軟性が向上し、不織布の加工性が向上する。   For example, after the resin single fiber bundle 23a is made into the composite yarn 20b, crimping or false twisting techniques can be diverted for the purpose of imparting flexibility to the composite yarn. By using crimping and false twisting techniques, the flexibility of the fibers is improved and the processability of the nonwoven fabric is improved.

また、本発明の実施形態に係る不織布10は経方向、斜方向及び逆斜方向に複合糸を積層させた三軸組布である。この場合は、経糸11と、斜交糸12や逆斜交糸13との交差角度は60±10°が好ましい。   Moreover, the nonwoven fabric 10 which concerns on embodiment of this invention is a triaxial assembly fabric which laminated | stacked the composite yarn in the warp direction, the diagonal direction, and the reverse diagonal direction. In this case, the crossing angle between the warp 11 and the oblique yarn 12 or the reverse oblique yarn 13 is preferably 60 ± 10 °.

さらに、この三軸組布に緯方向にも複合糸を加えることができる。すなわち、経方向、緯方向、斜方向及び逆斜方向に複合糸を積層させた四軸組布とすることもできる。この場合、緯糸は、経方向に対して、直交することとなる。なお、四軸組布の場合は、経糸または緯糸と、斜交糸又は逆斜交糸との交差角度は45±10°が好ましい。四軸組布とすると強度に優れ、更にねじれた場合の強度にも優れる。   Furthermore, a composite yarn can be added to the triaxial fabric in the weft direction. That is, a four-axis assembly fabric in which composite yarns are laminated in the warp direction, the weft direction, the oblique direction, and the reverse oblique direction can be used. In this case, the weft is orthogonal to the warp direction. In the case of a four-axis assembly, the crossing angle between the warp or weft and the oblique or reverse oblique yarn is preferably 45 ± 10 °. A four-axis assemblage is excellent in strength, and also excellent in strength when twisted.

また、本実施形態においては芯部樹脂21aとしてポリプロピレンを用い、鞘部樹脂22aとしてポリエチレンを用いているが、使用用途や必要とされる特性に応じて任意に別の樹脂とすることができる。具体的には、芯部樹脂21aとしてポリエチレンテレフタレート、ポリアミド(ナイロン)、鞘部樹脂22aとしてこれらより低融点の樹脂や各種共重合樹脂が挙げられる。特に、本発明の不織布をセメント系の補強材として用いる場合には、芯部樹脂21a及び鞘部樹脂22aが耐アルカリ性の熱可塑性樹脂であるのが好ましく、ポリオレフィンを使用するのが更に好ましい。芯部樹脂21aをポリオレフィンとすることにより追随性及び作業性が優れるようになる。また、芯部樹脂21a及び鞘部樹脂22aが共にポリオレフィンである場合は芯部樹脂21a及び鞘部樹脂22aの親和性が優れるため、鞘部樹脂22aであるポリオレフィンが溶融したとしても、芯部樹脂21aであるポリオレフィンから分離することなく芯鞘構造を維持することができる。また、ポリオレフィンは無極性であることから、酸や塩基にも強く、耐久性に優れる不織布を製造することができる。   Further, in the present embodiment, polypropylene is used as the core resin 21a and polyethylene is used as the sheath resin 22a. However, another resin can be arbitrarily selected depending on the intended use and required characteristics. Specifically, the core resin 21a includes polyethylene terephthalate and polyamide (nylon), and the sheath resin 22a includes resins having a melting point lower than these and various copolymer resins. In particular, when the nonwoven fabric of the present invention is used as a cement-based reinforcing material, the core resin 21a and the sheath resin 22a are preferably alkali-resistant thermoplastic resins, and more preferably polyolefins. By making the core resin 21a polyolefin, followability and workability are improved. Further, when both the core resin 21a and the sheath resin 22a are polyolefin, the affinity of the core resin 21a and the sheath resin 22a is excellent. Therefore, even if the polyolefin as the sheath resin 22a is melted, the core resin The core-sheath structure can be maintained without being separated from the polyolefin 21a. In addition, since polyolefin is nonpolar, it is possible to produce a nonwoven fabric that is strong against acids and bases and has excellent durability.

図6は、他の実施形態に係る不織布40を示す平面図である。不織布40は、経方向に複数並列した経糸11と、経糸11と斜交するように複数並列した斜交糸12と、経糸11及び斜交糸12に斜交するように複数並列した逆斜交糸13と、から構成されている。ここで経糸11は、斜交糸12及び逆斜交糸13の接面の一方面側と他方面側に交互に接着している。   FIG. 6 is a plan view showing a nonwoven fabric 40 according to another embodiment. The nonwoven fabric 40 includes a plurality of warp yarns 11 arranged in parallel in the warp direction, a plurality of oblique yarns 12 arranged in parallel so as to obliquely intersect with the warp yarns 11, and a plurality of parallel oblique yarns obliquely intersected with the warp yarns 11 and the oblique yarns 12. And a thread 13. Here, the warp yarns 11 are alternately bonded to one side and the other side of the contact surface of the oblique yarn 12 and the reverse oblique yarn 13.

このような構造の不織布40は、特に強度に優れ、更にねじれた場合の強度にも優れる。また、コンクリート剥落防止材に用いるとコンクリートの形状にかかわらず強度を発揮するため特に耐久性に優れ有用である。
また、不織布40の製造方法は、経糸11を斜交糸12及び逆斜交糸13の接面の一方面側のみに引き揃え接着した後、他方面側に経糸11を引き揃え接着させて製造される。
The nonwoven fabric 40 having such a structure is particularly excellent in strength, and further excellent in strength when twisted. Further, when used as a concrete exfoliation preventive material, it exhibits excellent strength regardless of the shape of the concrete and is particularly excellent in durability and useful.
Further, the nonwoven fabric 40 is manufactured by aligning and bonding the warp yarn 11 to only one side of the contact surface of the oblique yarn 12 and the reverse oblique yarn 13 and then aligning and adhering the warp yarn 11 to the other surface side. Is done.

<複合糸の製造>
芯部樹脂の熱可塑性樹脂としてMFR=20(g/min)のアイソタクチックポリプロピレンを使用し、鞘部樹脂としてMI(190℃)=20(g/min)の低密度ポリエチレン樹脂を使用した。定法の複合紡糸設備、芯鞘型複合紡糸ノズル(150H)を用いて紡糸した。得られた樹脂単繊維を150本集束し、これと直結する延伸設備に通して、絶対圧4.2kPa(145℃)の飽和水蒸気圧下で全延伸倍率14倍のローラー延伸を行い、(直ちに所定形状の成形ダイスに通して、)島部樹脂のポリプロピレン繊維(融点165℃)を海部樹脂の低密度ポリエチレン(融点113℃)で結着した略楕円状の複合糸(島部樹脂と海部樹脂の質量比=55:45)を得た。
得られた複合糸は2200dtexで、島部樹脂の単繊維径33.6μmであり、強度6.0cN/dtexであった。
<Manufacture of composite yarn>
An isotactic polypropylene with MFR = 20 (g / min) was used as the thermoplastic resin for the core resin, and a low density polyethylene resin with MI (190 ° C.) = 20 (g / min) was used as the sheath resin. Spinning was performed using a conventional composite spinning equipment, a core-sheath type composite spinning nozzle (150H). The obtained single resin fibers are bundled and passed through a stretching facility directly connected thereto, and then roller stretching at a total stretching ratio of 14 times is performed under a saturated water vapor pressure of 4.2 kPa (145 ° C.) in absolute pressure. Through a molding die having a shape, a substantially elliptical composite yarn (island resin and sea part resin) formed by binding polypropylene resin (melting point 165 ° C.) of island part resin with low density polyethylene (melting point 113 ° C.) of sea part resin. Mass ratio = 55: 45) was obtained.
The obtained composite yarn was 2200 dtex, the single fiber diameter of the island resin was 33.6 μm, and the strength was 6.0 cN / dtex.

<不織布Aの製造>
得られた複合糸を経糸、緯糸として図5に示す製造装置にて、経糸、斜交糸および逆斜交糸を9mmピッチで積層した。その際、経糸は上下層に交互に配置するように、斜交糸および逆斜交糸は中間層に位置するように積層した。その後、表面温度150℃の加熱ローラで接触加熱し、複合糸の海部樹脂を溶融し各層の複合糸を接着し不織布Aを得た。
(比較例)
<Manufacture of non-woven fabric A>
The obtained composite yarn was used as warp and weft, and the warp yarn, the oblique yarn and the reverse oblique yarn were laminated at a pitch of 9 mm in the production apparatus shown in FIG. At that time, the warp yarns and the reverse oblique yarns were laminated so as to be located in the intermediate layer so that the warp yarns were alternately arranged in the upper and lower layers. Thereafter, contact heating was performed with a heating roller having a surface temperature of 150 ° C., the sea part resin of the composite yarn was melted, and the composite yarn of each layer was bonded to obtain a nonwoven fabric A.
(Comparative example)

<不織布Bの製造>
番手2000dtex(フィラメント本数750本)のビニロン繊維糸を経糸、斜交糸、逆斜交糸とし、それぞれ実施例と同様のピッチで積層した。次いで、アクリル系接着剤に含浸し、表面温度150℃の加熱ローラで接触加熱して、接着剤の付着量がビニロン繊維糸に対し20重量%の不織布Bを得た。
<Manufacture of non-woven fabric B>
Vinylon fiber yarns having a count of 2000 dtex (750 filaments) were used as warp yarns, oblique yarns, and reverse oblique yarns, which were laminated at the same pitch as in the examples. Next, it was impregnated with an acrylic adhesive and heated by contact with a heating roller having a surface temperature of 150 ° C. to obtain a non-woven fabric B having an adhesive adhesion amount of 20% by weight based on the vinylon fiber yarn.

<試験例1>
不織布A及びBを折り曲げた場合の追随性について試験を行った。実施例の不織布Aは折り目が簡単につき、折り曲がった形状をそのまま維持していたが、比較例の不織布Bは折り目が付き難く、もとの形状に戻ろうとする反発力が強く折曲がった形状を維持することが困難であった。
<Test Example 1>
A test was conducted on the followability when the nonwoven fabrics A and B were bent. The non-woven fabric A of the example had a simple fold, and maintained the bent shape as it was, but the non-woven fabric B of the comparative example was not easily creased, and the repulsive force to return to the original shape was strongly bent. It was difficult to maintain.

<試験例2>
JIS規格 R3420 ガラス繊維一般試験方法 7.4(a)織物の引張強さの試験方法に準じ、引張強さを測定した。幅25mmの試験片について経糸方向(経方向)の引張強さと、幅50mmの試験片について経糸方向と直交する方向(緯方向)の引張強さを測定したところ、実施例の不織布Aは経方向370N/25mm、緯方向37N/50mmであり、比較例の不織布Bは経方向480N/25mm、緯方向23N/50mmであった。
<Test Example 2>
JIS standard R3420 Glass fiber general test method 7.4 (a) Tensile strength was measured according to the test method of tensile strength of fabrics. When the tensile strength in the warp direction (warp direction) was measured for a test piece with a width of 25 mm and the tensile strength in the direction (weft direction) perpendicular to the warp direction was measured for a test piece with a width of 50 mm, the nonwoven fabric A of the example was warp direction. The nonwoven fabric B of the comparative example had a warp direction of 480 N / 25 mm and a weft direction of 23 N / 50 mm.

経方向の引張強さは経糸の材質によるものであり、緯方向の引張強さは糸同士の接着力の差によるものであると考えられる。したがって、実施例の不織布Aは比較例の不織布Bと比較して材質面では強度に劣るが、接着力の面では強度に優れる。すなわち実施例の不織布Aは各複合糸が強固に接着しているため、特に緯方向の接着力に優れ強度が向上し、且つ追随性にも優れていることがわかる。   The tensile strength in the warp direction is due to the material of the warp, and the tensile strength in the weft direction is considered to be due to the difference in adhesive strength between the yarns. Therefore, although the nonwoven fabric A of an Example is inferior in intensity | strength in terms of a material compared with the nonwoven fabric B of a comparative example, it is excellent in intensity | strength in terms of adhesive force. That is, it can be seen that the nonwoven fabric A of the example has excellent adhesive strength in the weft direction, improved strength, and excellent followability because each composite yarn is firmly bonded.

実施形態に係る不織布を示す平面図である。It is a top view which shows the nonwoven fabric which concerns on embodiment. 図1のP部を拡大した斜視図である。It is the perspective view which expanded the P section of FIG. (a)は集束した樹脂単繊維を示す斜視図であり、(b)は本発明の不織布に用いることのできる複合糸を示す斜視図である。(A) is a perspective view which shows the converged resin single fiber, (b) is a perspective view which shows the composite yarn which can be used for the nonwoven fabric of this invention. (a)は図1に係る不織布の経糸11と斜交糸12との接面と逆斜交糸13の位置関係を示す平面図、(b)は本発明に係る不織布の経糸11と斜交糸12との接面と逆斜交糸13の位置関係の一形態を示す平面図である。(A) is a plan view showing the positional relationship between the contact surface of the non-woven warp 11 and the oblique yarn 12 and the reverse oblique yarn 13 according to FIG. 1, and (b) is the oblique cross with the non-woven warp 11 according to the present invention. FIG. 4 is a plan view showing one form of a positional relationship between a contact surface with the yarn 12 and a reverse oblique yarn 13. (a)は経糸群、緯糸群が送られた状態のドラム及びトラバーサを示す平面図、(b)はドラム、トラバーサ、及び緯糸送り出し機構を示す正面図である。(A) is a plan view showing the drum and the traverser in a state where the warp group and the weft group are fed, and (b) is a front view showing the drum, the traverser and the weft feeding mechanism. 他の実施形態に係る不織布を示す平面図である。It is a top view which shows the nonwoven fabric which concerns on other embodiment.

符号の説明Explanation of symbols

10,40・・・不織布、11・・・経糸、12・・・斜交糸、13・・・逆斜交糸、20a・・・樹脂単繊維束、20b・・・複合糸、21a・・・芯部樹脂、21b・・・島部樹脂、22a・・・鞘部樹脂、22b・・・海部樹脂、23a・・・樹脂単繊維、30・・・不織布製造装置、31・・・ドラム、32・・・回転軸、33a,33b・・・糸掛具、34・・・トラバーサ、35・・・緯糸送り出し機構、36・・・貫通孔、T1…経糸群、T2…緯糸群、T3・・・斜交糸群。   10, 40 ... Nonwoven fabric, 11 ... Warp, 12 ... Oblique yarn, 13 ... Reverse oblique yarn, 20a ... Resin single fiber bundle, 20b ... Composite yarn, 21a ... Core resin, 21b ... island resin, 22a ... sheath resin, 22b ... sea resin, 23a ... resin single fiber, 30 ... nonwoven fabric manufacturing apparatus, 31 ... drum, 32 ... Rotating shaft, 33a, 33b ... Thread hook, 34 ... Traverser, 35 ... Weft feed mechanism, 36 ... Through hole, T1 ... Warn group, T2 ... Weft group, T3. ..An oblique thread group.

Claims (8)

繊維状の芯部樹脂がこれより20℃以上融点の低い鞘部樹脂で囲繞された芯鞘構造を有する樹脂単繊維を複数本集束し、前記鞘部樹脂を融合させてなる複合糸を、
経方向、斜方向及び逆斜方向の少なくとも3方向に積層する積層工程と、
積層した複合糸同士を前記芯部樹脂の融点より低く、且つ前記鞘部樹脂の融点より高い温度で加熱して接着する接着工程と、を備える不織布の製造方法。
A composite yarn obtained by bundling a plurality of resin single fibers having a core-sheath structure in which a fibrous core resin is surrounded by a sheath resin having a melting point of 20 ° C. or more lower than that, and fusing the sheath resin,
A laminating step of laminating in at least three directions of warp direction, oblique direction and reverse oblique direction;
A method for producing a nonwoven fabric, comprising: a step of heating and bonding the laminated composite yarns at a temperature lower than the melting point of the core resin and higher than the melting point of the sheath resin.
前記複合糸は10〜500本の前記樹脂単繊維からなるものであり、前記複合糸において、前記芯部樹脂は繊度1〜70dtexの繊維状の島部を形成し、融合した前記鞘部樹脂は海部を形成している請求項1記載の不織布の製造方法。   The composite yarn is composed of 10 to 500 single resin fibers. In the composite yarn, the core resin forms a fibrous island having a fineness of 1 to 70 dtex, and the sheath resin is fused. The manufacturing method of the nonwoven fabric of Claim 1 which has formed the sea part. 前記芯部樹脂及び前記鞘部樹脂がポリオレフィンである請求項1又は2に記載の不織布の製造方法。   The method for producing a nonwoven fabric according to claim 1 or 2, wherein the core resin and the sheath resin are polyolefin. 前記芯部樹脂がポリプロピレンであって、前記鞘部樹脂が融点120℃以下のポリエチレンである請求項1〜3のいずれか一項に記載の不織布の製造方法。   The method for producing a nonwoven fabric according to any one of claims 1 to 3, wherein the core resin is polypropylene and the sheath resin is polyethylene having a melting point of 120 ° C or lower. 繊度1〜70dtexの繊維状の島部樹脂10〜500本が繊維状の海部樹脂中に配された複合糸を、経方向、斜方向及び逆斜方向の少なくとも3方向に積層し、海部樹脂を溶融させて積層した複合糸同士を接着した不織布であって、前記海部樹脂が前記島部樹脂より20℃以上低い融点を有することを特徴とする不織布。   A composite yarn in which 10 to 500 fibrous island resin having a fineness of 1 to 70 dtex is arranged in a fibrous sea resin is laminated in at least three directions of warp, oblique and reverse oblique directions. A nonwoven fabric obtained by bonding composite yarns that are melted and laminated to each other, wherein the sea part resin has a melting point that is 20 ° C. or more lower than that of the island part resin. 前記島部樹脂及び前記海部樹脂がポリオレフィンである請求項5記載の不織布。   The nonwoven fabric according to claim 5, wherein the island resin and the sea resin are polyolefin. 前記島部樹脂がポリプロピレンであって、前記海部樹脂が融点120℃以下のポリエチレンであることを特徴とする請求項5又は6に記載の不織布。   The nonwoven fabric according to claim 5 or 6, wherein the island resin is polypropylene, and the sea resin is polyethylene having a melting point of 120 ° C or lower. 前記島部樹脂と前記海部樹脂の質量比が、20:80〜80:20である請求項5〜7のいずれか一項に記載の不織布。   The nonwoven fabric according to any one of claims 5 to 7, wherein a mass ratio of the island resin and the sea resin is 20:80 to 80:20.
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