JPH07109658A - Nonwoven filament cloth having pattern and its production - Google Patents

Abstract

PURPOSE:To provide a process for applying a preset pattern no a nonwoven cloth by using an arbitrarily controlled program and to provide a nonwoven cloth having the pattern. CONSTITUTION:In a nonwoven cloth composed of filaments having a single fiber denier of <=15de, the opening state 3 of the fibers constituting the nonwoven cloth is varied to an arbitrary preset pattern and the fiber is collected to obtain a decorative nonwoven cloth having an arbitrary pattern developed on the nonwoven cloth. This invention also relates to a production process of the nonwoven cloth.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention improves the appearance and commercial value by imparting a decorative property to a non-woven fabric used for interior goods such as wallpaper, packaging materials, and other household goods related goods by imparting a pattern. The present invention relates to a patterned long-fiber nonwoven fabric and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, for interior goods such as wallpaper, packaging materials, and other gift goods, various kinds of paper are mainly printed in order to improve the image of the goods.
A variety of slightly printed films have entered the market. Furthermore, in recent years, long-fiber non-woven fabrics have also entered into these applications.

The decorativeness imparting means for improving the appearance and the commercial value of the above-mentioned non-woven fabric is subjected to another value-added process such as printing, embossing, needle punching for patterning, or other process. To produce a non-woven fabric with decorative properties such as coating of decorative materials, addition of value-added processing to add other decorative materials such as laminating and flocking, and having a decorative property by itself.
After attaching a mold to the special-shaped collecting conveyor having a concavo-convex pattern when collecting the non-woven fabric, or patterning the hole shape,
No effective production means was found except for a very specific limited example of a method for producing a perforated nonwoven fabric using a final embossing calendar or the like.

[0004]

However, the long-fiber non-woven fabric is effective because it is superior in tear strength as compared with paper and film, but due to defects such as streaks and spots, it cannot be combined with other materials. It is necessary to use and print the spun yarn, which increases the cost and makes it difficult to expand the sales.

Further, in order to eliminate these drawbacks, it is known to apply a high-pressure water stream to a long fiber non-woven fabric to give a pattern, but it is difficult to give a large pattern.
The physical properties of the non-woven fabric were partially deteriorated.

Further, a method for producing a perforated non-woven fabric by using a final embossing calendar or the like after placing a mold on a specially-shaped collecting conveyor having an uneven pattern at the time of collecting the non-woven fabric or patterning the perforated shape However, there is a drawback in that it takes a lot of time and cost to change the pattern, and the advantage of imparting the pattern to the non-woven fabric is negated.

The present invention does not rely on a patterning process in a separate process for imparting decorative properties to a long-fiber non-woven fabric by patterning, and has a unique common facility and function of processes in the non-woven fabric manufacturing process. Partly improved, no special additional processing equipment is required, capital investment by introducing additional processing equipment,
A method of applying a pattern to a non-woven fabric with a set pattern by setting a process condition that is easy and easy to implement by an arbitrarily controlled program without increasing the man-hours for performing another process and increasing the process cost. A non-woven fabric is provided.

[0008]

According to the present invention, a non-woven fabric composed of long fibers having a single yarn denier of 15 denier or less is collected by changing the opened state of the non-woven fabric constituent fibers into an arbitrary pattern state as set. The present invention provides a non-woven fabric having a decorative property in which a non-woven fabric exhibits an arbitrary pattern and a method for producing the same.

That is, according to the present invention, the difference in the converged state (opened state) of the fibers constituting the nonwoven fabric can be imparted under arbitrarily controlled programming, and the desired pattern based on the difference in the light transmittance is designed as the nonwoven fabric. Focusing on the fact that it can be applied to the non-woven fabric, the idea is to open the non-woven fabric yarn band by the repulsion by electrostatic charge that can be controlled arbitrarily, and electrify it under the control of the programmed electrostatic field to form an arbitrary pattern. We have developed a method of imparting an arbitrary pattern to a non-woven fabric by giving high and low electrification level and presence / absence of electrostatic electrification to make a difference in opened state, and a patterned non-woven fabric.

[0010]

[Function] Regarding the opening of the yarn band, it has long been known in the textile industry that the yarn band is already placed in an electrostatic field and electrostatically charged to open the fiber by electrical repulsion. The towed yarn band is pulled and spun at a high speed and taken by an air jet device for towing, and the yarn band is jetted from the air jet device for towing along with a high-speed air flow for towing on a traveling conveyor to disperse it evenly. The so-called spunbond method for producing a nonwoven fabric by distributed sedimentation is also disclosed after the application of the electrostatic opening method in the method described in Japanese Patent Publication No. 37-4993, after the spun yarn band is opened. It is known to apply the electrostatic charging method to produce homogeneous non-woven fabrics, and many modified applications are used and known.

The difference in the level of the charged state in these processes, or the presence or absence of the charge, gives a large difference in the opened state of the spun yarn, which causes a difference in the light transmittance of the collected non-woven fabric and a large difference in the appearance. Show.

That is, according to the method of the present invention, in the spunbonding nonwoven fabric manufacturing process to which the ordinary electrostatic fiber opening method is applied, the spun yarn strips discharged from the nozzles arranged in the width direction of the apparatus are arranged. , A grounded electrostatic fiber-spreading device is charged in accordance with a set program in order to electrostatically charge and electrostatically spread the fiber in a high-speed spinning device that pulls, jets, and transfers it toward a grounded collecting conveyor that runs. A very simple and efficient method for imparting a set arbitrary pattern to a nonwoven fabric by charging the film with a predetermined width, a predetermined time, a predetermined voltage, or a on-off charge has been developed.

For example, in the electrostatic fiber opening device, when a non-woven fabric is produced by charging by setting a charged zone-an uncharged zone in an intermittent state at a fixed predetermined width interval, a nonwoven fabric having a stripe pattern of a predetermined width is produced. It can be manufactured and is programmed to move this intermittent charged-uncharged band across the width over time, which corresponds to the charge band-uncharged width shift and the collection conveyor travel speed. A non-woven fabric having a diagonal stripe pattern can be manufactured.

At this time, if the electrostatic load is applied intermittently, the striped pattern can be made into an intermittent pattern. Furthermore, using a computer, the set width in the width direction of the charged zone-non-charged zone,
By arbitrarily controlling various variables such as the interval, the transfer speed in the width direction, and the charging time, it is possible to develop a diamond pattern or a simple company name logo on the nonwoven fabric.

As described above, the present invention is based on the difference in the light transmissivity based on the difference in the converged state of the non-woven fabric constituent fibers. Therefore, the condition that the effect of the present invention can be exerted is the single fiber denier of the non-woven fabric constituent fibers. However, it must be 15 denier or less. Single fiber denier of non-woven fabric is 1
When it exceeds 5 denier, the effect of opening the fiber is small, the gap between the fibers per unit weight is large, and the pattern is not clear.

Further, in the present invention, the non-woven fabric constituent fiber giving a preferable result can sufficiently utilize the electrostatic charging effect,
Polyester synthetic fibers to which the spunbond method can be applied,
Polyamide-based synthetic fibers and polyolefin-based synthetic fibers are particularly preferable, but not limited to these.

Further, due to the current electric field effect range of electric fiber opening, it is difficult to form a pattern having a width direction of 10 mm or less. Furthermore, the electric field is charged on the fiber, and it takes a time for opening the fiber to be within 1 second. The pattern of the nonwoven fabric in the longitudinal direction is determined by the relationship between the opening time and the speed of the collection conveyor. Since the present invention does not change the fiber density or the adhesion state, there is no great difference in the tensile strength and tear strength between the opened portion and the unopened portion.

[0018]

EXAMPLES Examples of the present invention will be described below. The apparatus shown in FIGS. 1 and 2 is used to manufacture the long-fiber nonwoven fabric according to the present invention. In the figure, a filament F is spun downward from a nozzle 1 of a spinneret, passes through a cooling duct 2, and then is sent to an electric fiber opener 3. The electric opener 3
The filament F is composed of a large number of needle electrodes 4 and an electrode plate 5. The filament F passes between the needle electrode 4 and the electrode plate 5, is charged and opened during the passage, and then the charged filament F.
Is sucked by the suction jet 6 having a width of 1 m, and shaken off on the collection net conveyor 7. Then, the filament F on the collection net conveyor 7 is thermocompression-bonded by the embossing calender 8 at 160 ° C. to form a pattern-formed long-fiber nonwoven fabric.

The nozzle 1 is supplied with polyester having an intrinsic viscosity of 0.63, and has a hole diameter of 0.3 mm and a length of 0.9.
3700 mm orifices are evenly distributed in a width of 1 m, and the filament has a single hole of 1.78 g.
It is continuously extruded in the shape of a blind from the above orifice at a rate of 1 / min.

In the cooling duct, the filament is cooled by an air flow of 26 ° C. Also, suction jet 6
The electric fiber-spreading device 3 is installed at a position of 100 mm above, but the needle electrodes 4 arranged facing the electrode plate 5 are arranged in a width of 1 m, a vertical pitch of 1 cm, and a vertical pitch of 4 rows. Has been done. The distance between the needle electrode group 4 and the electrode plate 5 is 30 m.
m, and when a voltage of 20 KV is applied and discharge is generated, a current of about 1 A flows. The on / off timing of the voltage applied to each needle electrode is controlled according to a program preset by the computer.

An example of a method of supplying power to the needle electrode 4 of the electric fiber opening device 3 will be described. First, a set of 100 needle electrodes 4 is formed in the width direction, with four vertically installed sets as one set. Switches are respectively connected between these groups and the high-voltage DC power source, and these 100 groups of switches are controlled to be turned on and off according to a sequence pre-programmed in the computer to sequentially form switching zones. Each switch is on the high voltage side, and from the viewpoint of insulation, for example, a phototransistor is used as the switch. It is preferable that the phototransistor emit light in response to turning on and off according to a command from a computer, and the light emission is sent to the phototransistor through an optical cable to turn the phototransistor on and off.

Next, an example in which a specific pattern is formed will be described. (Example 1) The manufacturing apparatus shown in FIGS. 1 and 2 is used, but in the needle electrode 4 of the electric spreader 3, a width of 10 cm (4
A switching zone corresponding to 0 needles is provided, and the applied voltage to this zone is turned on / off to turn on / off the electric opening of this zone. The way of moving this zone is set in advance in a computer program, and the on / off of the electric opening is sequentially moved to either the left or right of the traveling direction at a speed of 5 cm per second. Simultaneously with this movement, the collection net conveyor 7 is moved to 20 minutes per minute.
Send at a speed of m.

In this case, a diagonal pattern appears on the non-woven fabric, and the angle is determined by the on / off lateral moving speed of electric opening and the feeding speed of the collecting net. In this embodiment,
As shown in FIG. 3, when the applied voltage is turned on, the filament is opened and the region 10 having excellent shielding property is obtained.
Then, by turning off the applied voltage, the filaments are converged to form the region 11 having excellent transparency, and a non-woven fabric having an oblique pattern of 8 ° with respect to the traveling direction is formed.

(Embodiment 2) A two-beam structure, for example, two stages of the manufacturing apparatus shown in FIG. 1 are prepared so that the yarn bands overlap in two layers in the traveling direction, and they are shaken off on the same collecting net conveyor 7. . And in each electric open device 3, 10
A switching zone corresponding to a cm width (40 needles) is provided, and the on / off movement speed of the zone in the left-right direction is set to 12 cm per second, and the first beam, that is, the switching zone of one electric opener 3 is advanced. When moved to the right side in the direction, the second beam, that is, the other electric fiber opening device 3 is moved to the left side in the traveling direction, and this is repeated alternately. By controlling these on / off by a computer set in advance in a program, as shown in FIG. 4, when the applied voltage is turned on, the filament 12 is opened and the region 12 having excellent shielding property, When the applied voltage is turned off, the filaments are converged to form the region 13 having excellent transparency, and a diamond pattern with four light and dark colors and a tip angle of 30 ° is synthesized.

(Embodiment 3) In the manufacturing apparatus shown in FIG. 1, the collection net conveyor 7 is fed at 60 cm / min, and
By applying a 0 cm square dot pattern, "TOYOBO" characters having a character size of 80 cm square as shown in FIG. 5 are developed on the nonwoven fabric. As shown in FIG. 6 in which a part of the nonwoven fabric is enlarged, these are divided into a region 14 in which the filaments are opened and excellent in shielding property, and a region 15 in which the filaments are converged and excellent in permeability.

First, a dot matrix is created corresponding to the on / off switching zone of the needle electrode 4 of the electric fiber opening device 3 with the desired logo mark. Next, a variable dimension for required dots is created in the computer. Data is input with the coordinates of the matrix as X (i, j). i is a variable in the horizontal direction of the collection net conveyor 7, for example, 1 to 11, j is a variable in the feeding direction of the collection net conveyor 7,
For example, 1 to 44. For the portion that expresses the characters "TOYOBO", that is, for the dot portion to be electrically opened, the process output that is ON with X (i, j) = 1 is set, and for the other portion, X (i, j) = 0 is set. As
Write the program so that each process output is turned off. The timer is set in consideration of the speed of the collecting net conveyor in the j direction and the j direction at the same time. X (i,
By changing j) = 0 or 1 variously, a simple pattern can be formed in addition to the characters.

Table 1 shows the characteristic values of the prototypes and the non-patterned non-woven fabrics according to Examples 1, 2 and 3. In Table 1, tensile strength and tear strength are basis weight 1 g / m.
It is a value per ² .

[0028]

[Table 1]

As shown in Table 1, since the present invention does not change the fiber density or the adhesion state, the physical properties such as the tensile and tear strength of the nonwoven fabric having the pattern by opening and the nonwoven fabric having no pattern are large. There is no difference.

[0030]

According to the present invention, the following outstanding effects can be obtained. (1) Packaging material of long-fiber non-woven fabric excellent in tearability, paper bag,
It is possible to produce decorative materials such as wallpaper at low cost. (2) Each long fiber non-woven fabric containing each user name can be switched without any trouble by changing the computer program. (3) A spunbonded non-woven fabric is obtained in which it is difficult to find defects such as streaks and spots due to the pattern.

[Brief description of drawings]

FIG. 1 is a schematic side view of a patterned continuous fiber nonwoven fabric manufacturing apparatus according to an embodiment of the present invention.

FIG. 2 is a schematic front view of a patterned continuous fiber nonwoven fabric manufacturing apparatus according to an embodiment of the present invention.

FIG. 3 is a schematic view of a non-woven fabric having a diagonal pattern according to an embodiment of the present invention.

FIG. 4 is a schematic view of a diamond-patterned non-woven fabric according to an embodiment of the present invention.

FIG. 5 is a schematic view of a logo mark non-woven fabric according to an embodiment of the present invention.

FIG. 6 is a partially enlarged schematic view of a logo mark non-woven fabric according to an embodiment of the present invention.

[Explanation of symbols]

 1 Nozzle 2 Cooling Duct 3 Electric Fiber Opener 4 Needle Electrode 5 Electrode Plate 6 Suction Jet 7 Collection Net Conveyor 8 Embossing Calender 10 Area where the filament is opened and has excellent shielding property 11 Filament converges and has excellent permeability Area 12 Filament is opened and has excellent shielding property 13 Filament is converged and area is excellent in permeability 14 Filament is opened and area is excellent in shielding property 15 Filament is converged and excellent in permeability Area

Claims (2)

[Claims] 1. A non-woven fabric comprising long fibers having a denier of 15 denier or less, and a long-fiber non-woven fabric with a pattern in which an arbitrary pattern is formed on the surface of the non-woven fabric. 2. A method for producing a non-woven fabric composed of long fibers having a denier of 15 denier or less, wherein the convergent state of the yarn strips constituting the non-woven fabric is controlled according to an arbitrarily set program so that the electrostatic charge state of the yarn strips is controlled. A method for producing a patterned long-fiber non-woven fabric, which comprises expressing a desired pattern in the non-woven fabric by partially and discontinuously changing the electric open state to collect the non-woven fabric.