JP2015193955A - Three-layer structure nonwoven fabric having raised pattern and method for manufacturing the same - Google Patents
Three-layer structure nonwoven fabric having raised pattern and method for manufacturing the same Download PDFInfo
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- JP2015193955A JP2015193955A JP2014072809A JP2014072809A JP2015193955A JP 2015193955 A JP2015193955 A JP 2015193955A JP 2014072809 A JP2014072809 A JP 2014072809A JP 2014072809 A JP2014072809 A JP 2014072809A JP 2015193955 A JP2015193955 A JP 2015193955A
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- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 101
- 238000004519 manufacturing process Methods 0.000 title claims description 12
- 238000000034 method Methods 0.000 title description 6
- 229920000728 polyester Polymers 0.000 claims abstract description 100
- 239000000835 fiber Substances 0.000 claims abstract description 99
- 229920000742 Cotton Polymers 0.000 claims abstract description 84
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 56
- 239000010410 layer Substances 0.000 claims description 36
- 238000002844 melting Methods 0.000 claims description 26
- 239000002344 surface layer Substances 0.000 claims description 26
- 239000002131 composite material Substances 0.000 claims description 12
- 239000000470 constituent Substances 0.000 claims description 9
- 230000004927 fusion Effects 0.000 claims description 4
- 238000010030 laminating Methods 0.000 claims 1
- 238000003825 pressing Methods 0.000 claims 1
- 238000004049 embossing Methods 0.000 abstract description 18
- 230000001747 exhibiting effect Effects 0.000 abstract 1
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 18
- 230000008018 melting Effects 0.000 description 18
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 9
- 239000002184 metal Substances 0.000 description 9
- 238000009987 spinning Methods 0.000 description 9
- 229920001225 polyester resin Polymers 0.000 description 6
- 239000004645 polyester resin Substances 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 4
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 4
- -1 polyethylene terephthalate Polymers 0.000 description 4
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 3
- 150000002009 diols Chemical class 0.000 description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 description 3
- 239000005020 polyethylene terephthalate Substances 0.000 description 3
- 238000007334 copolymerization reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000002074 melt spinning Methods 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000003484 crystal nucleating agent Substances 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
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- Nonwoven Fabrics (AREA)
Abstract
【課題】エンボス加工によって得られるのと同等な明確な浮き出し模様を、高圧水流によって現した三層構造不織布を提供する。
【解決手段】ポリエステル長繊維不織布１０の表裏面に、コットン繊維で構成された層１１，１２が積層されてなる三層構造不織布。表裏両層１１，１２を構成するコットン繊維は、ポリエステル長繊維と高圧水流によって交絡され、更に、コットン表面１１に孔開き模様を有する孔開き版１４を当接させ、コットン裏面１２側が前記高圧水流より高い圧力の高圧水流を施して、孔開き版１４の孔開き模様をコットン表面１１に浮き出し模様として付与した三層構造不織布。またポリエステル長繊維の横断面形状は、略Ｙ４形状となっている。
【選択図】図８The present invention provides a three-layered nonwoven fabric exhibiting a clear relief pattern equivalent to that obtained by embossing by a high-pressure water stream.
A three-layer nonwoven fabric in which layers 11 and 12 composed of cotton fibers are laminated on the front and back surfaces of a polyester long-fiber nonwoven fabric 10. The cotton fibers constituting both the front and back layers 11 and 12 are entangled with the polyester long fibers by a high-pressure water stream, and further, a perforated plate 14 having a perforated pattern is brought into contact with the cotton surface 11 so that the cotton back surface 12 side is the high-pressure water stream. A three-layered nonwoven fabric in which a perforated pattern of the perforated plate 14 is provided as a raised pattern on the cotton surface 11 by applying a high-pressure water flow at a higher pressure. Moreover, the cross-sectional shape of the polyester continuous fiber is substantially Y4 shape.
[Selection] Figure 8
Description
本発明は、不織布表面に各種図柄や文字等の模様が明確に浮き上がって現れており、不織布裏面は平滑な状態となっている浮き出し模様を持つ三層構造不織布及びその製造方法に関するものである。 The present invention relates to a three-layer structure nonwoven fabric having a raised pattern in which various patterns, characters, and other patterns are clearly raised on the surface of the nonwoven fabric and the nonwoven fabric back surface is in a smooth state, and a method for producing the same.
従来より、不織布表面に明確な浮き出し模様を現し、不織布裏面は平滑な状態となっている浮き出し模様を持つ不織布は、エンボス加工によって得るのが一般的であった（特許文献１）。また、不織ウェブをネット状織物の上に置いて、高圧水流を施すことにより、ネット状の凹凸模様を持つ不織布が得られることも知られている（特許文献２）。しかしながら、この凹凸模様は、不織布の表裏面両者に現れるものである。しかも、凹凸模様も明確な浮き出し模様とはいえず、模様の境界も不明瞭なものである。したがって、上記のエンボス加工に比べて、明確な浮き出し模様を得ることはできなかった。 Conventionally, a non-woven fabric having an embossed pattern in which a clear embossed pattern appears on the surface of the non-woven fabric and the back surface of the non-woven fabric is smooth is generally obtained by embossing (Patent Document 1). It is also known that a nonwoven fabric having a net-like uneven pattern can be obtained by placing a nonwoven web on a net-like woven fabric and applying a high-pressure water stream (Patent Document 2). However, this uneven pattern appears on both the front and back surfaces of the nonwoven fabric. Moreover, the uneven pattern is not a clear relief pattern, and the boundary between the patterns is also unclear. Therefore, a clear embossed pattern could not be obtained as compared with the above embossing.
本発明の課題は、エンボス加工法ではなく、高圧水流を施す方法において、エンボス加工によって得られるのと同等な明確な浮き出し模様を持つ不織布を提供するものである。 An object of the present invention is to provide a non-woven fabric having a clear embossing pattern equivalent to that obtained by embossing in a method of applying a high-pressure water flow instead of an embossing method.
本発明は、特殊な横断面形状を持つ構成繊維よりなる不織布を中間層として用いることにより、上記課題を解決したものである。すなわち、本発明は、ポリエステル長繊維で構成されてなるポリエステル不織布の表裏面に、コットン繊維を主体として構成されてなる表面層及び裏面層が積層されてなり、表面層及び裏面層を構成する該コットン繊維は、該ポリエステル長繊維と高圧水流によって交絡されている三層構造不織布であって、前記ポリエステル長繊維層を構成するポリエステル長繊維の横断面形状は、略Ｙ字の下端で上下左右に連結した
形状（以下、「略Ｙ４形状」という。）であって、該ポリエステル長繊維相互間は熱融着によって結合されており、前記表面層を構成するコットン繊維は高圧水流の作用によって外方へ浮き出て、前記表面層に浮き出し模様が現れており、前記裏面層を構成するコットン繊維は外方へ浮き出ることなく、前記裏面層は平滑であることを特徴とする浮き出し模様を持つ三層構造不織布及びその製造方法に関するものである。
This invention solves the said subject by using the nonwoven fabric which consists of a constituent fiber with a special cross-sectional shape as an intermediate | middle layer. That is, in the present invention, the front and back surfaces of a polyester nonwoven fabric composed of polyester long fibers are laminated with a front surface layer and a back surface layer mainly composed of cotton fibers, and constitute the front surface layer and the back surface layer. The cotton fiber is a three-layered nonwoven fabric entangled with the polyester long fiber by high-pressure water flow, and the cross-sectional shape of the polyester long fiber constituting the polyester long fiber layer is substantially Y-shaped at the top, bottom, left and right. Connected
The polyester long fibers are bonded to each other by heat fusion, and the cotton fibers constituting the surface layer are lifted outward by the action of a high-pressure water flow. A three-layered nonwoven fabric having a raised pattern, wherein a raised pattern appears on the surface layer, the cotton fibers constituting the back layer do not float outward, and the back layer is smooth, and It relates to the manufacturing method.
まず、本発明で用いられるポリエステル長繊維について説明する。このポリエステル長繊維は、その横断面形状に特徴を有するものである。この横断面形状は、図１に示すような略Ｙ字を四個持つものである。そして、略Ｙ字の下端１で上下左右に連結して、図２に示すような略Ｙ４形状となっている。この略Ｙ４形状は、四個の凹部２と八個の凸部３と四個の小凹部４とを有している。このように多数の凹部２、多数の小凹部４、多数の凸部３を持っており、嵩高性に優れているため、このポリエステル長繊維が集積されて長繊維相互間が結合していても、高圧水流の通過性が良好である。そして、中央の略＋字部５と、略＋字部５の各先端に連結された四個の略Ｖ字部６により、高剛性となっている。すなわち、六角形やＹ字等の単なる異形ではなく、剛性の高い略＋字部５と略Ｖ字部６の組み合わせによって、より高剛性となるのである。かかるポリエステル長繊維を集積し、ポリエステル長繊維相互間を熱融着することにより結合して、本発明で用いる嵩高で且つ高剛性のポリエステル不織布を得ることができる。 First, the polyester continuous fiber used by this invention is demonstrated. This polyester continuous fiber is characterized by its cross-sectional shape. This cross-sectional shape has four substantially Y-characters as shown in FIG. And it is connected to the upper and lower sides and the right and left at the lower end 1 of a substantially Y shape, and has a substantially Y4 shape as shown in FIG. The substantially Y4 shape has four concave portions 2, eight convex portions 3, and four small concave portions 4. In this way, it has a large number of concave portions 2, a large number of small concave portions 4, and a large number of convex portions 3, and is excellent in bulkiness. Therefore, even if the polyester long fibers are accumulated and the long fibers are bonded to each other. The passage of high-pressure water flow is good. Further, high rigidity is achieved by the substantially + -shaped part 5 at the center and the four approximately V-shaped parts 6 connected to the respective tips of the approximately + -shaped part 5. In other words, it is not a simple shape such as a hexagon or a Y-shape, but a higher rigidity is achieved by a combination of the substantially + -shaped portion 5 and the substantially V-shaped portion 6 having high rigidity. Such polyester long fibers are accumulated and bonded by heat-sealing the polyester long fibers to obtain a bulky and highly rigid polyester nonwoven fabric used in the present invention.
ポリエステル長繊維は、一種類のポリエステルからなるものでもよいが、低融点ポリエステルと高融点ポリエステルとを組み合わせるのが好ましい。すなわち、ポリエステル長繊維の横断面形状の略Ｖ字部６が低融点ポリエステルで形成され、略＋字部５が高融点ポリエステルで形成された複合型するのが好ましい。複合型ポリエステル長繊維を集積した後、低融点ポリエステルを軟化又は溶融させた後、固化させることにより、ポリエステル長繊維相互間が低融点ポリエステルによって熱融着されたポリエステル不織布が得られるからである。また、ポリエステル不織布を構成するポリエステル長繊維の繊度は、１０デシテックス以上であるのが好ましい。繊度が１０デシテックス未満になると、長繊維の剛性が低下する傾向が生じ、ひいてはポリエステル不織布の剛性も低下する傾向が生じる。また、ポリエステル不織布の目付は、２０〜７０ｇ／ｍ2以上であるのが好ましい。目付が２０ｇ／ｍ2未満になると、ポリエステル不織布の剛性が低下する傾向が生じる。目付が７０ｇ／ｍ2を超えると、高圧水流の通過性が低下する傾向が生じる。なお、本発明で用いるポリエステル不織布の詳細については、特開２０１３−７６１８２号公報に詳述されている。 The polyester continuous fiber may be composed of one kind of polyester, but it is preferable to combine a low-melting polyester and a high-melting polyester. That is, it is preferable to use a composite type in which the substantially V-shaped portion 6 of the cross-sectional shape of the polyester long fiber is formed of low-melting polyester and the substantially + -shaped portion 5 is formed of high-melting polyester. This is because the polyester nonwoven fabric in which the polyester long fibers are heat-fused with the low melting point polyester is obtained by softening or melting the low melting point polyester after the composite type polyester long fibers are accumulated and then solidifying. Moreover, it is preferable that the fineness of the polyester long fiber which comprises a polyester nonwoven fabric is 10 decitex or more. When the fineness is less than 10 dtex, the rigidity of the long fibers tends to decrease, and as a result, the rigidity of the polyester nonwoven fabric tends to decrease. Moreover, it is preferable that the fabric weight of a polyester nonwoven fabric is 20-70 g / m < 2 > or more. When the basis weight is less than 20 g / m 2 , the polyester nonwoven fabric tends to have low rigidity. If the basis weight exceeds 70 g / m 2 , the high-pressure water flow tends to deteriorate. In addition, the detail of the polyester nonwoven fabric used by this invention is explained in full detail in Unexamined-Japanese-Patent No. 2013-76182.
ポリエステル不織布の表裏面には、コットン繊維を主体として構成されてなる表面層及び裏面層が積層されている。表面層及び裏面層はコットン繊維が主体となって構成されているが、その他のレーヨン短繊維、ポリエステル短繊維、ポリアミド短繊維等が若干量含まれていてもよい。表面層を構成するコットン繊維は、ポリエステル不織布中のポリエステル長繊維と交絡している。この交絡は、表面層側から高圧水流を施すことにより形成されたものである。また、裏面層を構成するコットン繊維も、ポリエステル不織布中のポリエステル長繊維と交絡している。この交絡も、裏面層側から高圧水流を施すことにより形成されたものである。この高圧水流は、コットン繊維とポリエステル長繊維とを交絡させるためのもので、一般的に、孔径０．０５〜２．０ｍｍの噴射孔から、３〜６ＭＰａの圧力で水が噴射されて得られるものである。 On the front and back surfaces of the polyester nonwoven fabric, a surface layer and a back surface layer mainly composed of cotton fibers are laminated. The front surface layer and the back surface layer are mainly composed of cotton fibers, but may contain a small amount of other rayon short fibers, polyester short fibers, polyamide short fibers and the like. The cotton fibers constituting the surface layer are entangled with the polyester long fibers in the polyester nonwoven fabric. This entanglement is formed by applying a high-pressure water flow from the surface layer side. Moreover, the cotton fiber which comprises a back layer is also entangled with the polyester long fiber in a polyester nonwoven fabric. This entanglement is also formed by applying a high-pressure water flow from the back layer side. This high-pressure water stream is for entanglement of cotton fibers and polyester long fibers, and is generally obtained by injecting water at a pressure of 3 to 6 MPa from an injection hole having a hole diameter of 0.05 to 2.0 mm. Is.
表面層を構成するコットン繊維は、外方へ浮き出て浮き出し模様を形成している。この浮き出し模様の一例は図３に示したとおりであり、「Ｄｉｌｌａ」の文字からなる模様が四方に連続している浮き出し模様である。表面層の浮き出し模様は、裏面層側から表面層に向けて、高圧水流を施すことにより、形成されるものである。この高圧水流の圧力は、コットン繊維とポリエステル長繊維とを交絡させるための高圧水流の圧力よりも高くなっている。すなわち、この高圧水流は、孔径０．０５〜２．０ｍｍの噴射孔から、７〜１０ＭＰａの圧力で水が噴射されて得られるものである。なお、裏面層は、浮き出し模様が形成されることはなく、平滑な状態となっている。 The cotton fibers constituting the surface layer are raised outward to form a raised pattern. An example of this embossed pattern is as shown in FIG. 3, and is an embossed pattern in which a pattern composed of characters “Dilla” is continuous in all directions. The raised pattern on the surface layer is formed by applying a high-pressure water stream from the back layer side toward the surface layer. The pressure of the high-pressure water flow is higher than the pressure of the high-pressure water flow for entanglement of the cotton fibers and the polyester long fibers. That is, this high-pressure water flow is obtained by injecting water at a pressure of 7 to 10 MPa from an injection hole having a hole diameter of 0.05 to 2.0 mm. In addition, the back surface layer is in a smooth state without forming a raised pattern.
表面層に浮き出し模様を持つ本発明に係る三層構造不織布は、以下のような製造工程を経ることにより、得ることができる。まず、前記したポリエステル不織布を準備する。そして、ポリエステル不織布の表面に、コットン繊維を主体として集積されてなるコットン表面ウェブを積層する。また、ポリエステル不織布の裏面にも、コットン繊維を主体として集積されてなるコットン裏面ウェブを積層する。この三層積層ウェブに、コットン表面ウェブ側から高圧水流を施して、コットン表面ウェブを構成しているコットン繊維とポリエステル不織布中のポリエステル長繊維とを交絡する。また、コットン裏面ウェブ側からも高圧水流を施して、コットン裏面ウェブを構成しているコットン繊維とポリエステル不織布中のポリエステル長繊維とを交絡する。これによって、三層が一体化した積層物が得られる。 The three-layer structure nonwoven fabric according to the present invention having a raised pattern on the surface layer can be obtained through the following production steps. First, the above-described polyester nonwoven fabric is prepared. And the cotton surface web formed by mainly collecting cotton fibers is laminated on the surface of the polyester nonwoven fabric. Moreover, the cotton back surface web formed by mainly collecting cotton fibers is laminated on the back surface of the polyester nonwoven fabric. A high-pressure water flow is applied to the three-layer laminated web from the cotton surface web side, and the cotton fibers constituting the cotton surface web and the polyester long fibers in the polyester nonwoven fabric are entangled. Moreover, a high pressure water flow is given also from the cotton back surface web side, and the cotton fiber which comprises the cotton back surface web and the polyester long fiber in the polyester nonwoven fabric are entangled. Thereby, a laminate in which the three layers are integrated is obtained.
孔開き模様を有する孔開き板を準備し、上記積層物のコットン表面ウェブが，この孔開き板に当接するようにして載置する。この孔開き板は、金属板やプラスチック板の如き剛直な板に所定の孔開き模様を穿孔したものである。そして、積層物のコットン裏面ウェブ側から高圧水流を施す。この高圧水流は、前の工程で施した高圧水流に比べて、圧力が高くなっている。したがって、コットン裏面ウェブからポリエステル不織布を通過して、コットン表面ウェブに到達し、コットン表面ウェブのコットン繊維は孔開き板の孔に押し込められるのである。これによって、表面層に浮き出し模様が現れた三層構造不織布が得られるのである。 A perforated plate having a perforated pattern is prepared and placed so that the cotton surface web of the laminate is in contact with the perforated plate. This perforated plate is obtained by punching a predetermined perforated pattern in a rigid plate such as a metal plate or a plastic plate. Then, a high-pressure water flow is applied from the cotton back web side of the laminate. This high-pressure water stream has a higher pressure than the high-pressure water stream applied in the previous step. Therefore, the polyester non-woven fabric passes through the polyester nonwoven fabric and reaches the cotton surface web, and the cotton fibers of the cotton surface web are pushed into the holes of the perforated plate. As a result, a three-layered nonwoven fabric having a raised pattern on the surface layer is obtained.
本発明において、表面層に明確な浮き出し模様が現れる原理を図に基づいて説明すれば、以下のとおりである。図４は積層物を孔開き板に当接するようして載置した状態を示した側面図であり、１０はポリエステル不織布、１１はコットン表面ウェブ、１２はコットン裏面ウェブ、１３は孔開き板であり、１４は孔開き板１３中の孔である。この状態で、図５に示すように、コットン裏面ウェブ１２側から高圧水流（矢印）を施すと、コットン表面ウェブ１１のコットン繊維のみが孔開き板１３の孔１４に押し込められ、ポリエステル不織布１０は殆ど変形しない。コットン表面ウェブ１１のコットン繊維のみが孔１４に押し込められる理由は、ポリエステル不織布１０の構成繊維が特殊な横断面形状となっているので、構成繊維相互間に大きな空隙が形成されており、高圧水流の通過性がよく、コットン表面ウェブ１１まで水流が通過するからである。また、コットン表面ウェブ１１を構成しているコットン繊維は吸水性に優れ、水流によって膨潤して変形しやすくなり、コットン繊維のみが孔１４に押し込められるのである。また、ポリエステル不織布１０が殆ど変形しない理由は、ポリエステル不織布１０は高剛性だからである。なお、コットン裏面ウェブ１２は高剛性のポリエステル不織布１０に支持された状態となっているので、殆ど変形せずに平滑なままである。たとえば、横断面形状が略円形である長繊維を構成繊維とする長繊維不織布２０を用いると、構成繊維相互間に大きな空隙が形成されず、剛性も低いために、図６又は図８に示した状態となる。すなわち、コットン表面ウェブ１１中のコットン繊維のみが孔１４に押し込められるのではなく、長繊維不織布２０の構成繊維も共に孔１４に押し込められる。これは、長繊維不織布２０が良好に高圧水流を通過させずに、しかも低剛性であるため、孔１４に押し込められる方向に変形するのである。そうすると、コットン表面ウェブ１１と長繊維不織布２０とは同一挙動となるので、明確な浮き出し模様が現れないのである。 In the present invention, the principle that a clear relief pattern appears on the surface layer will be described with reference to the drawings. FIG. 4 is a side view showing a state in which the laminate is placed in contact with the perforated plate. 10 is a polyester nonwoven fabric, 11 is a cotton front web, 12 is a cotton back web, and 13 is a perforated plate. And 14 is a hole in the perforated plate 13. In this state, as shown in FIG. 5, when a high-pressure water flow (arrow) is applied from the cotton back web 12 side, only the cotton fibers of the cotton front web 11 are pushed into the holes 14 of the perforated plate 13, and the polyester nonwoven fabric 10 is Almost no deformation. The reason why only the cotton fibers of the cotton surface web 11 are pushed into the holes 14 is that the constituent fibers of the polyester nonwoven fabric 10 have a special cross-sectional shape, so that a large gap is formed between the constituent fibers, and the high-pressure water flow This is because the water flow passes through the cotton surface web 11. Further, the cotton fibers constituting the cotton surface web 11 are excellent in water absorption, easily swelled and deformed by a water flow, and only the cotton fibers are pushed into the holes 14. The reason why the polyester nonwoven fabric 10 hardly deforms is that the polyester nonwoven fabric 10 is highly rigid. Since the cotton back web 12 is supported by the high-rigidity polyester nonwoven fabric 10, the cotton back web 12 remains smooth with almost no deformation. For example, when the long fiber nonwoven fabric 20 having a long fiber having a substantially circular cross-sectional shape as a constituent fiber is used, a large gap is not formed between the constituent fibers and the rigidity is low. It becomes a state. That is, not only the cotton fibers in the cotton surface web 11 are pushed into the holes 14, but the constituent fibers of the long-fiber nonwoven fabric 20 are also pushed into the holes 14. This is because the long-fiber nonwoven fabric 20 does not pass through a high-pressure water flow well and has low rigidity, so that it deforms in a direction to be pushed into the hole 14. If it does so, since the cotton surface web 11 and the long-fiber nonwoven fabric 20 will become the same behavior, a clear embossing pattern does not appear.
本発明に係る三層構造不織布は、表面に明確な浮き出し模様を有しているので、意匠性に優れており、従来公知の種々の用途に用い得る。たとえば、袋の生地として用い、意匠性に優れた袋とすることができる。また、壁紙、拭き布、生理用ナプキンや使い捨ておむつの表面材又はバックシートとして用いることもできる。 Since the three-layered nonwoven fabric according to the present invention has a clear relief pattern on the surface, it is excellent in design and can be used for various conventionally known applications. For example, it can be used as a bag fabric and can be made into a bag with excellent design. Moreover, it can also be used as a wallpaper, a wipe, a sanitary napkin, a surface material of a disposable diaper, or a back sheet.
本発明に係る三層構造不織布は、特定のポリエステル不織布を中間層に、コットン繊維を主体とする層を表裏層として用いることにより、高圧水流の作用によって、明確な浮き出し模様を得ることができるという効果を奏する。特に、エンボス加工と同等な明確な浮き出し模様を、高圧水流の作用によって得ることができるという効果を奏する。 The three-layer structure nonwoven fabric according to the present invention uses a specific polyester nonwoven fabric as an intermediate layer and a layer mainly composed of cotton fibers as the front and back layers, so that a clear relief pattern can be obtained by the action of high-pressure water flow. There is an effect. In particular, there is an effect that a clear embossing pattern equivalent to embossing can be obtained by the action of high-pressure water flow.
実施例１
［ポリエステル不織布の製造例］
ジカルボン酸成分としてテレフタル酸（ＴＰＡ）９２ｍｏｌ％及びイソフタール酸（ＩＰＡ）８ｍｏｌ％を用い、ジオール成分としてエチレングリコール（ＥＧ）１００ｍｏｌ％を用いて共重合し、低融点ポリエステル（相対粘度〔ηｒｅｌ〕１．４４、融点２３０℃）を得た。この低融点ポリエステルに、結晶核剤として４．０質量％の酸化チタンを添加して、低融点ポリエステル樹脂を準備した。一方、ジカルボン酸成分としてテレフタル酸（ＴＰＡ）１００ｍｏｌ％とジオール成分としてエチレングリコール（ＥＧ）１００ｍｏｌ％を用いて共重合し、高融点ポリエステル樹脂（ポリエチレンテレフタレート、相対粘度〔ηｒｅｌ〕１．３８、融点２６０℃）を準備した。そして、図７に示したノズル孔を用い、Ｖ字部に低融点ポリエステル樹脂を供給し、＋字部に高融点ポリエステル樹脂を供給して、紡糸温度２８５℃、単孔吐出量８．３３ｇ／分で溶融紡糸した。なお、低融点ポリエステル樹脂の供給量と高融点ポリエステル樹脂の供給量の重量比は、１：２であった。
Example 1
[Production example of polyester nonwoven fabric]
Copolymerization was carried out using terephthalic acid (TPA) 92 mol% and isophthalic acid (IPA) 8 mol% as the dicarboxylic acid component, and ethylene glycol (EG) 100 mol% as the diol component, and a low-melting polyester (relative viscosity [ηrel] 1. 44, melting point 230 ° C.). To this low melting point polyester, 4.0% by mass of titanium oxide was added as a crystal nucleating agent to prepare a low melting point polyester resin. On the other hand, 100 mol% of terephthalic acid (TPA) as a dicarboxylic acid component and 100 mol% of ethylene glycol (EG) as a diol component were copolymerized to obtain a high melting point polyester resin (polyethylene terephthalate, relative viscosity [ηrel] 1.38, melting point 260). ℃) was prepared. Then, using the nozzle holes shown in FIG. 7, a low melting point polyester resin is supplied to the V-shaped part, and a high melting point polyester resin is supplied to the + -shaped part, and the spinning temperature is 285 ° C., the single-hole discharge rate is 8.33 g / Melt spun in minutes. In addition, the weight ratio of the supply amount of the low melting point polyester resin and the supply amount of the high melting point polyester resin was 1: 2.
ノズル孔から排出されたフィラメント群を、２ｍ下のエアーサッカー入口に導入し、複合型ポリエステル長繊維の繊度が１７デシテックスとなるように牽引した。エアーサッカー出口から排出された複合型ポリエステル長繊維群を開繊装置にて開繊した後、移動するネット製コンベア上に集積し、繊維ウェブを得た。この繊維ウェブを、表面温度が２１３℃のエンボスロール（各エンボス凸部先端の面積は０．７ｍｍ2で、ロール全面積に対するエンボス凸部の占める面積率は１５％）とフラットロールからなる熱融着装置に導入し、両ロール間の線圧３００Ｎ／ｃｍの条件として、複合型ポリエステル長繊維相互間を低融点成分で熱融着して、目付４０ｇ／ｍ2のポリエステル不織布を得た。 The filament group discharged from the nozzle hole was introduced into the air soccer entrance 2 m below and pulled so that the fineness of the composite polyester long fiber was 17 dtex. The composite polyester long fiber group discharged from the air soccer exit was opened with a fiber opening device and then collected on a moving net conveyor to obtain a fiber web. This fiber web is heat-fused with a flat roll and an embossing roll having a surface temperature of 213 ° C. (the area at the tip of each embossing protrusion is 0.7 mm 2 and the area ratio of the embossing protrusion relative to the total area of the roll is 15%). The polyester non-woven fabric having a basis weight of 40 g / m 2 was obtained by heat-sealing the composite polyester long fibers with a low melting point component as a condition of a linear pressure of 300 N / cm between both rolls.
このポリエステル不織布の表裏面に、目付４０ｇ／ｍ2のコットン繊維１００質量％からなるコットン繊維ウェブを積層し、コットン表面ウェブ／ポリエステル不織布／コットン裏面ウェブなる三層積層ウェブを得た。コットン繊維ウェブは、精錬・漂白したコットン繊維（繊維長約２５〜３５ｍｍ）を用いて、大和機工株式会社製のサンプルローラーカード機にて開繊集積して得たものである。この三層積層ウェブを１００メッシュのステンレスネット上に載せ、ノズル径０．１３ｍｍ、水圧４．１７ＭＰａの条件で、コットン表面ウェブ側から高圧水流を施した。次いで、三層積層ウェブを反転させて、コットン裏面ウェブ側から同様の条件で高圧水流を施して、三層が一体化した積層物を得た。 A cotton fiber web composed of 100% by mass of cotton fibers having a basis weight of 40 g / m 2 was laminated on the front and back surfaces of this polyester nonwoven fabric to obtain a three-layer laminated web of cotton surface web / polyester nonwoven fabric / cotton back web. The cotton fiber web is obtained by opening and accumulating with a sample roller card machine manufactured by Yamato Kiko Co., Ltd. using refined and bleached cotton fibers (fiber length of about 25 to 35 mm). This three-layer laminated web was placed on a 100-mesh stainless net, and a high-pressure water flow was applied from the cotton surface web side under the conditions of a nozzle diameter of 0.13 mm and a water pressure of 4.17 MPa. Next, the three-layer laminated web was inverted, and a high-pressure water flow was applied from the cotton back web side under the same conditions to obtain a laminate in which the three layers were integrated.
「Ｄｉｌｌａ」の文字からなる穿孔が四方に連続している金属製孔開き板を準備した。この金属製孔開き板を１００メッシュのステンレスネットの上に載置し、金属製孔開き板の表面がコットン表面ウェブが当接するようにして、上記積層物を孔開き板に載置した。そして、ノズル径０．１３ｍｍ、水圧８．３３ＭＰａの条件で高圧水流をコットン裏面ウェブ側から積層物に施した。その後、金属製孔開き板を取り外し、積層物を乾燥して、浮き出し模様を持つ三層構造不織布を得た。 A metal perforated plate in which perforations composed of the letters “Dilla” are continuous in all directions was prepared. This metal perforated plate was placed on a 100 mesh stainless net, and the laminate was placed on the perforated plate so that the surface of the metal perforated plate was in contact with the cotton surface web. Then, a high-pressure water flow was applied to the laminate from the cotton back web side under the conditions of a nozzle diameter of 0.13 mm and a water pressure of 8.33 MPa. Thereafter, the metal perforated plate was removed, and the laminate was dried to obtain a three-layered nonwoven fabric having a raised pattern.
得られた三層構造不織布は、コットン表面ウェブのコットン繊維が金属製孔開き板の穿孔の形状と近似した凸状態の模様となって、くっきりと明確に浮き出ていた。コットン裏面ウェブは、剛性に優れたポリエステル不織布に載置された状態となっているため、金属製孔開き板の穿孔に位置する箇所が凹むことなく平滑なプレーンな状態を維持した。得られた三層構造不織布は、片面は立体感ある模様を発現し、その反対面は平滑なプレーン状態であるボリューム感と品位に優れたものであった。また、剛性に優れたポリエステル不織布を中央に配し、表裏層をコットン繊維で構成したため、表裏層が柔らかく風合いに優れていた。 The obtained three-layered nonwoven fabric was clearly and clearly raised, with the cotton fibers of the cotton surface web having a convex pattern similar to the perforated shape of the metal perforated plate. Since the cotton back web was placed on a polyester nonwoven fabric excellent in rigidity, the portion located in the perforation of the metal perforated plate was maintained in a smooth and plain state without being recessed. The obtained three-layered nonwoven fabric exhibited a three-dimensional pattern on one side, and the opposite side was excellent in volume and quality in a smooth plain state. Moreover, since the polyester nonwoven fabric excellent in rigidity was arranged in the center and the front and back layers were made of cotton fibers, the front and back layers were soft and excellent in texture.
比較例１
［長繊維不織布の製造］
融点２６０℃、極限粘度［η］０．７０ポリエチレンテレフタレートを準備し、公知の溶融紡糸装置を用い、繊維の横断面が円形となる紡糸孔を３０個備えた紡糸口金より、紡糸温度２８０℃でポリエステル長繊維を溶融紡出した。紡糸口金とエアーサッカーまでの距離は１４０ｃｍに設定し、紡出長繊維をエアーサッカーに導入した。このとき、ひとつのエアーサッカーに３０本の長繊維を導入した。そして、エアーサッカーにて、長繊維の繊度が３．０デシテックスとなるように紡糸速度５０００ｍ／分で牽引し、紡出長繊維は、開繊装置でばらばらになるように開繊させた後、コンベアネット上に捕集・堆積させて、長繊維ウェブを得た。得られた長繊維ウエブを、エンボスロール（エンボスロールの凸部の面積０．４２ｍｍ2、面積率３７％）とフラットロールとからなる熱エンボス装置に導き、両ロールの表面温度２３５℃、線圧４９０Ｎ／ｃｍの条件下で部分的に熱圧接処理を施し、目付４０ｇ／ｍ2の長繊維不織布を得た。この長繊維不織布は、構成繊維である長繊維の横断面が円形であるため、実施例１で用いたポリエステル不織布に比べて、高圧水流の通過性が劣り、また剛性も低いものであった。
Comparative Example 1
[Manufacture of long-fiber nonwoven fabric]
A melting point of 260 ° C. and an intrinsic viscosity [η] 0.70 polyethylene terephthalate were prepared. Using a known melt spinning apparatus, a spinneret equipped with 30 spinning holes with a circular cross section of the fiber was used at a spinning temperature of 280 ° C. Polyester filaments were melt spun. The distance from the spinneret to the air soccer was set to 140 cm, and the spinning long fiber was introduced into the air soccer. At this time, 30 long fibers were introduced into one air soccer. Then, in air soccer, after pulling at a spinning speed of 5000 m / min so that the fineness of the long fiber becomes 3.0 dtex, the spun long fiber is opened by the opening device so as to be separated, A long fiber web was obtained by collecting and depositing on a conveyor net. The obtained long fiber web was led to a heat embossing device composed of an embossing roll (the area of the convex part of the embossing roll was 0.42 mm 2 and the area ratio was 37%) and a flat roll, and the surface temperature of both rolls was 235 ° C. and the linear pressure. A heat-welding process was partially applied under conditions of 490 N / cm to obtain a long fiber nonwoven fabric having a basis weight of 40 g / m 2 . Since this long fiber nonwoven fabric has a circular cross section of the long fibers, which are constituent fibers, it has poor high-pressure water flow and low rigidity compared to the polyester nonwoven fabric used in Example 1.
［三層不織布の製造］
実施例１で用いたポリエステル不織布に代えて、上記で得られた長繊維不織布を用いる他は、実施例１と同一の方法で三層不織布を得た。
得られた三層不織布は、中央に配した長繊維不織布が高圧水流を十分に通過させずに、しかも低剛性であるため、８．３３ＭＰａの圧力で噴射された高圧水流によって、長繊維不織布が金属製孔開き板の穿孔に対応して図６の如き態様で変形し、コットン表面ウェブに明確な浮き出し模様が形成されなかった。また、コットン裏面ウェブも、長繊維不織布が低剛性であるため、８．３３ＭＰａの圧力で噴射された高圧水流によって、図６の如き態様で変形し、平滑な状態を維持していなかった。
[Manufacture of three-layer nonwoven fabric]
Instead of the polyester nonwoven fabric used in Example 1, a three-layer nonwoven fabric was obtained by the same method as in Example 1 except that the long fiber nonwoven fabric obtained above was used.
The obtained three-layer nonwoven fabric has a long fiber nonwoven fabric placed in the center that does not sufficiently pass the high pressure water stream and has low rigidity. Therefore, the long fiber nonwoven fabric is formed by the high pressure water stream injected at a pressure of 8.33 MPa. Corresponding to the perforation of the metal perforated plate, it was deformed in the manner as shown in FIG. 6, and a clear relief pattern was not formed on the cotton surface web. Further, the cotton back web was also deformed in a manner as shown in FIG. 6 by the high-pressure water flow injected at a pressure of 8.33 MPa because the long fiber nonwoven fabric had low rigidity, and the smooth state was not maintained.
比較例２
［長繊維不織布の製造］
チーグラナッタ系重合触媒を用いて重合された、メルトフローレート２５ｇ／１０分、密度０．９５８ｇ／ｃｍ3及び融点１３０℃の高密度ポリエチレンを準備した。一方、ジカルボン酸成分としてテレフタル酸（ＴＰＡ）１００ｍｏｌ％とジオール成分としてエチレングリコール（ＥＧ）１００ｍｏｌ％を用いて共重合し、高融点ポリエステル（ポリエチレンテレフタレート、相対粘度〔ηｒｅｌ〕１．３８、融点２６０℃）を準備した。そして、公知の芯鞘型紡糸孔を備えた溶融紡糸装置にて、紡糸温度２８５℃、単孔吐出量２．５４ｇ／分で鞘部がポリエチレンで芯部がポリエステルの横断面円形である芯鞘複合型長繊維を溶融紡糸した。なお、高密度ポリエチレンの供給量と高融点ポリエステルの供給量の重量比は、１：２であった。紡糸孔から排出された複合型長繊維を、２ｍ下のエアーサッカー入口に導入し、複合型長繊維の繊度が６．６デシテックスとなるように牽引した。エアーサッカー出口から排出された複合型長繊維を開繊装置にて開繊した後、移動するネット製コンベア上に集積し、長繊維ウェブを得た。この長繊維ウェブを、表面温度が１２０℃のエンボスロール（各エンボス凸部先端の面積は０．７ｍｍ2で、ロール全面積に対するエンボス凸部の占める面積率は１５％）とフラットロールからなる熱融着装置に導入し、両ロール間の線圧３００Ｎ／ｃｍの条件で熱融着して、目付１５ｇ／ｍ2の鞘部がポリエチレン、芯部がポリエステルの芯鞘型複合長繊維からなる長繊維不織布を得た。この長繊維不織布は、構成繊維である複合型長繊維の横断面が円形であるため、実施例１で用いたポリエステル不織布に比べて、高圧水流の通過性が劣り、また剛性も低いものであった。特に、低目付であるため、比較例１で用いた長繊維不織布に比べて、剛性の低いものであった。
Comparative Example 2
[Manufacture of long-fiber nonwoven fabric]
A high density polyethylene having a melt flow rate of 25 g / 10 min, a density of 0.958 g / cm 3 and a melting point of 130 ° C., polymerized using a Ziegler-Natta polymerization catalyst was prepared. On the other hand, copolymerization was performed using 100 mol% of terephthalic acid (TPA) as a dicarboxylic acid component and 100 mol% of ethylene glycol (EG) as a diol component, and a high melting point polyester (polyethylene terephthalate, relative viscosity [ηrel] 1.38, melting point 260 ° C. ) Was prepared. Then, in a melt spinning apparatus equipped with a known core-sheath type spinning hole, a core-sheath having a spinning temperature of 285 ° C., a single-hole discharge rate of 2.54 g / min, a sheath part of polyethylene and a core part of a circular cross section of polyester. Composite long fibers were melt spun. In addition, the weight ratio of the supply amount of the high density polyethylene and the supply amount of the high melting point polyester was 1: 2. The composite long fiber discharged from the spinning hole was introduced into the air soccer entrance 2 m below and pulled so that the fineness of the composite long fiber was 6.6 dtex. The composite long fibers discharged from the air soccer exit were opened with a fiber opening device, and then accumulated on a moving net conveyor to obtain a long fiber web. This long fiber web is heated with an embossing roll having a surface temperature of 120 ° C. (the area at the tip of each embossing protrusion is 0.7 mm 2 and the area ratio of the embossing protrusion to the total area of the roll is 15%) and a flat roll. Introduced into a fusing device, heat-sealed under the condition of a linear pressure of 300 N / cm between both rolls, and a length consisting of a core-sheath type composite continuous fiber having a sheath with a basis weight of 15 g / m 2 and a core with a polyester A fiber nonwoven fabric was obtained. This long fiber nonwoven fabric has a circular cross section of the composite long fiber, which is a constituent fiber, and therefore has a poor high-pressure water flow and low rigidity compared to the polyester nonwoven fabric used in Example 1. It was. In particular, since it has a low basis weight, it has a lower rigidity than the long-fiber nonwoven fabric used in Comparative Example 1.
［三層不織布の製造］
実施例１で用いたポリエステル不織布に代えて、上記で得られた長繊維不織布を用いる他は、実施例１と同一の方法で三層不織布を得た。
得られた三層不織布は、中央に配した長繊維不織布が高圧水流を十分に通過させずに、しかも低剛性であるため、８．３３ＭＰａの圧力で噴射された高圧水流によって、長繊維不織布が金属製孔開き板の穿孔に対応して図８の如き態様で変形した。すなわち、長繊維不織布が比較例１のものに比べても低剛性であるため、コットン裏面ウェブも長繊維不織布自体も、８．３３ＭＰａの圧力で噴射された高圧水流によって、図８の如き態様で変形し、平滑な状態を維持していなかった。
[Manufacture of three-layer nonwoven fabric]
Instead of the polyester nonwoven fabric used in Example 1, a three-layer nonwoven fabric was obtained by the same method as in Example 1 except that the long fiber nonwoven fabric obtained above was used.
The obtained three-layer nonwoven fabric has a long fiber nonwoven fabric placed in the center that does not sufficiently pass the high pressure water stream and has low rigidity. Therefore, the long fiber nonwoven fabric is formed by the high pressure water stream injected at a pressure of 8.33 MPa. Corresponding to the drilling of the metal perforated plate, it was deformed in the manner as shown in FIG. That is, since the long fiber non-woven fabric is less rigid than that of Comparative Example 1, both the cotton back web and the long fiber non-woven fabric itself are in the form shown in FIG. 8 by the high-pressure water flow injected at a pressure of 8.33 MPa. It was deformed and did not maintain a smooth state.
１ ポリエステル長繊維の横断面形状である略Ｙ４形状の一つの略Ｙ字の下端
２ 略Ｙ４形状で形成された凹部
３ 略Ｙ４形状で形成された凸部
４ 略Ｙ４形状で形成された小凹部
５ 略Ｙ４形状中の略＋字部
６ 略Ｙ４形状中の略Ｖ字部
１０ ポリエステル不織布
１１ コットン表面ウェブ
１２ コットン裏面ウェブ
１３ 孔開き板
１４ 孔開き板中の孔
２０ 長繊維不織布
DESCRIPTION OF SYMBOLS 1 Lower end of one substantially Y shape of the substantially Y4 shape which is the cross-sectional shape of a polyester continuous fiber 2 The recessed part formed in the substantially Y4 shape 3 The convex part formed in the substantially Y4 shape 4 The small recessed part formed in the substantially Y4 shape 5 About + character part in about Y4 shape 6 About V-shaped part in about Y4 shape 10 Polyester nonwoven fabric 11 Cotton surface web 12 Cotton back surface web 13 Perforated plate 14 Hole in perforated plate 20 Long fiber nonwoven fabric
Claims (4)
前記ポリエステル長繊維層を構成するポリエステル長繊維の横断面形状は、略Ｙ字の下端で上下左右に連結した
形状（以下、「略Ｙ４形状」という。）であって、該ポリエステル長繊維相互間は熱融着によって結合されており、
前記表面層を構成するコットン繊維は高圧水流の作用によって外方へ浮き出て、前記表面層に浮き出し模様が現れており、
前記裏面層を構成するコットン繊維は外方へ浮き出ることなく、前記裏面層は平滑であることを特徴とする浮き出し模様を持つ三層構造不織布。 The front and back surfaces of a polyester nonwoven fabric composed of polyester long fibers are laminated with a surface layer and a back surface layer mainly composed of cotton fibers, and the cotton fibers constituting the surface layer and the back surface layer are the polyester. A three-layered nonwoven fabric entangled with long fibers and high-pressure water flow,
The cross-sectional shape of the polyester long fiber constituting the polyester long fiber layer is connected to the top, bottom, left and right at the lower end of a substantially Y shape.
A shape (hereinafter referred to as “substantially Y4 shape”), and the polyester filaments are bonded together by heat fusion,
The cotton fibers constituting the surface layer are raised outward by the action of a high-pressure water stream, and a raised pattern appears on the surface layer,
A three-layered nonwoven fabric having an embossed pattern, wherein the back surface layer is smooth without the cotton fibers constituting the back layer being raised outward.
前記三層構造ウェブの前記コットン表面ウェブ側から高圧水流を施して、前記コットン表面ウェブを構成しているコットン繊維と前記ポリエステル長繊維とを交絡させる工程、 前記三層構造ウェブの前記コットン裏面ウェブ側から高圧水流を施して、前記コットン裏面ウェブを構成しているコットン繊維と前記ポリエステル長繊維とを交絡させる工程及び、
前記コットン表面ウェブに孔開き模様を有する孔開き板を当接させて、コットン裏面ウェブ側から、前記各高圧水流よりも高い圧力の高圧水流を施して、前記コットン表面ウェブを構成するコットン繊維を孔開き板の孔開き模様中に押し込める工程を具備することを特徴とする浮き出し模様を持つ三層構造不織布の製造方法。 Cotton surface formed mainly of cotton fibers on the front and back surfaces of a polyester nonwoven fabric comprising polyester long fibers having a substantially Y4 cross-sectional shape as constituent fibers, and the polyester long fibers bonded together by thermal fusion. A step of preparing a three-layer web formed by laminating a web and a cotton back web;
A step of applying a high-pressure water flow from the cotton surface web side of the three-layer structure web to entangle the cotton fibers constituting the cotton surface web and the polyester long fibers, the cotton back surface web of the three-layer structure web A step of applying a high-pressure water flow from the side to entangle the cotton fibers constituting the cotton back web and the polyester continuous fibers; and
A cotton fiber constituting the cotton surface web is obtained by bringing a perforated plate having a perforated pattern into contact with the cotton surface web, and applying a high pressure water flow at a pressure higher than each of the high pressure water flows from the cotton back web side. A method for producing a three-layered nonwoven fabric having an embossed pattern, comprising a step of pressing into a perforated pattern of a perforated plate.
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