JP2881672B2 - Three-dimensional nonwoven fabric and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION An object of the present invention is to provide a new material by using a nonwoven fabric.

[0002]

2. Description of the Related Art Saw washers, moldings, and the like conventionally used for cleaning and decoration use fibers or strings incorporated in fibers, and the manufacturing process is complicated and costly. Was. Also, as a microbial carrier, a string-like contact material (“Biocode” T)
(Made by BS (machine)), but the process was complicated, the productivity was low and expensive, the contact area was small, and it was easy to set.
Therefore, the inventors of the present application have considered using a cylindrical three-dimensional nonwoven fabric obtained by flat or spiral winding of a nonwoven fabric instead of such a material.

[0003]

However, since the cylindrical three-dimensional non-woven fabric is formed by winding a sheet-like non-woven fabric, the tensile strength is low and the non-woven fabric is broken when a strong tension is applied during use. Also, there is a problem that the fibers are easily arranged in the circumferential direction and have no resistance to compression. In addition, because the surface has a continuous structure,
Since it is difficult to absorb external force, and gives a hard touch or deforms when deformed, it is not suitable for a molding for decoration, for example. Furthermore, since the surface area is small, when it is used for a microorganism carrier, for example, the contact area with the microorganism is small, and the porous structure of the nonwoven fabric cannot be fully utilized.

[0004]

The present invention provides a completely new material, a three-dimensional nonwoven fabric having a radially pleated cross section and a linear joint, by utilizing a nonwoven fabric. To provide. Further, the invention of this application is to form a linear joint at an interval on one or a plurality of laminated nonwoven fabrics, and to cut between the linear joint and the linear joint. And a method for producing the three-dimensional nonwoven fabric.

According to the invention of this application, as shown in FIG. 1, by forming linear joining portions 2 at intervals on one or a plurality of laminated nonwoven fabrics 1, a linear nonwoven fabric having a predetermined thickness is formed. By forming a strongly compressed part and cutting the non-woven fabric between these linear joints, the thickness of the non-woven fabric at the cut location is recovered and integrated at the fold joint made of non-woven fabric pieces The obtained three-dimensional nonwoven fabric has a cross section having radial folds. When there is an interval between the folds, a three-dimensional nonwoven fabric having a petal-shaped cross section is obtained as shown in FIG. 2, and when there is no interval, a three-dimensional nonwoven fabric having a columnar shape is obtained as shown in FIG.

The linear joint 2 may be linear or wavy, solid, dashed or dotted. The joint can be formed by a sealing means such as a heat seal, an ultrasonic seal, or a high frequency seal, an adhesive means by applying an adhesive, or a sewing means by sewing such as a sewing machine. In the case of using a sealing means or an adhesive means, the width of the linear joint is preferably 1 to 5 mm.
If thermoplastic fibers cannot be used as the constituent fibers of the nonwoven fabric, an adhesive means or a suturing means should be used. However, if they can be used, a joint means having a higher tensile strength can be formed by using a sealing means.

[0007] The cutting of the nonwoven fabric between the linear joints is performed by using a three-dimensional nonwoven fabric having a petal-like cross section or a columnar three-dimensional nonwoven fabric having a uniform cross section in the right and left direction. In the case of manufacturing, the cutting is performed in the middle of the line segment of both joints, and in the case of manufacturing a cross section having an uneven left and right side, the cutting may be performed at a position offset to one of the line segments. The cutting line 3 is preferably a straight line, but may be a wavy line if necessary.

The production by the method of the present invention will be specifically described with reference to an example. One or a plurality of nonwoven fabrics containing heat-fusible fibers are laminated, and the lamination thickness (Tcm) is set to a slit width (Wcm). Set so that 2T ≧ 45/360 × πW. (Depending on the material of the nonwoven fabric, 2T <45
/ 360 × πW makes it difficult to obtain a three-dimensional nonwoven fabric satisfying the physical properties required for the present invention). The set product is continuously sealed (heat, ultrasonic wave, high frequency) or stitched at a constant width interval, and then cut into Wcm width. When the relationship between the lamination thickness and the slit width is 2T <πW, the cross-sectional shape is a petal shape, and when 2T ≧ πW, the cross-sectional shape is a molding (circular). At this time, it is preferable that the cushioning nonwoven fabric and the hard wide nonwoven fabric are overlapped and sealed. If the sealing portion contains at least 20% (preferably 35%) or more of heat-fusible fibers and / or heat-fusible resin (mesh or woven fabric is also possible), the strength is high. A string or a wire can be inserted into the seal portion.

The relationship between the cross-sectional shape, the lamination thickness (Tcm) and the slit width (Wcm) of the three-dimensional nonwoven fabric is as follows. (1) When the linear joint is at the center of the slit width a. When 2T <πW, the gap between the pleats disappears and the petals open. (2T ≧ (1 / 3πW to 1 / 4π
In the case of W), the petals open uniformly, and 2T <(1 / 3π
(W to 1 / 4πW), the petals tend to open unevenly. B. When 2T ≧ πW, the gap between the folds is eliminated, and the fiber layers on the outer peripheral surface are connected to form a molding. (If the thickness Tcm further increases due to the compression at the time of sealing, it may become a molding even at 2T <πW.) (2) When the linear joint is not at the center of the slit width, as shown in FIG. distance from the cutting line to one of the joint is as long as W _1, when the distance to the other joint portion is short and W _2, when T <the πW _1, becomes petals, T
When ≧ πW _2, the shape becomes a molding.

As a joining method, when an adhesive component is contained in the nonwoven fabric itself, it is preferable to use a sealing means such as an ultrasonic seal, a high frequency seal, a heat seal or the like. Since the shape of the seal portion is continuous, the strength is improved. I do. In addition, it is also possible to seal discontinuously. The seal width may be any value, but a width of 1 to 5 mm is preferable. When strength is required, a larger width is better. In order to reinforce the strength, a string, a mesh, or a woven or knitted material may be put on the sealing portion or on the entire surface. When a thermoplastic fiber is used as the adhesive component in the nonwoven fabric, it is desirable that the nonwoven fabric be composed mainly of polyolefin, polyester, polyamide, polyvinylidene chloride, and acrylic fibers. In the case of vinylon or polyvinyl alcohol fiber, it can be sealed with wet heat and pressure. The direction of the seal may be either the vertical direction or the horizontal direction. The ratio of these thermoplastic fibers varies depending on the required tensile strength, flexibility, or the width of the seal portion and the thickness of the seal portion, and the type of fibers involved in the adhesion in the laminated nonwoven fabric. It is desirable that the proportion of the fibers involved in the heating be at least 20 wt% or more, preferably 40 wt% or more. Even if less than 20 wt%, a seal can be obtained, but it is not suitable for applications requiring high tensile strength and shape retention. However, these problems can be solved when sealing with a hot melt adhesive and when inserting a string or a mesh knitted fabric as a reinforcing material. Also,
Adhesive means using an adhesive may be used as a means for forming a linear joint, and in this case, an adhesive (for example, ethylene and an ethylene copolymer, a copolymer polyamide, a copolymer polyester, a polypropylene, a vinyl acetate copolymer, Cellulose derivative, acrylic resin, polyurethane)
What is necessary is just to press-fit (press-fit) while compressing a base material.

The material obtained by the present invention has, for example, the following uses depending on the respective functions. For scouring and brushing, scourers, loofahs, car wash brushes, household scrubbers; for carriers, microbial immobilization carriers for water purification, artificial seaweed, artificial soil; for filters, liquid filters, air conditioning filters, vacuum cleaners The filters are drainage materials such as water pipes and civil engineering drainage materials.Water absorption materials are sweat catches, water absorption pads and anti-condensation materials.Oil absorption materials are oil catchers, oil fences, and oil absorption materials. The material is a cold insulation muffler as a heat insulating material, a substitute for ropes wound around trees, the hood is a sound absorbing material for sound absorption in ducts, and the shock absorbing material is a corner, protector, gym mat, etc. As materials, as a cushion, a pillow, a backrest, a shoulder pad,
As strings, ropes, strings, band strings, strings for hair, rods, pillars, FRP cores, curlers, etc., sirocco fan blades, windmills, three-dimensional picture books, doll stuffed toys, shoes In place of deodorant type, mall, bamboo sword,
Used as a cushion building block.

[0012] The use and the material and shape of the raw materials will be further described. For the purpose of purifying water and for the carrier for immobilizing microorganisms, BOC, CO such as rivers, lakes and marshes, and the sea can be used.
D, nitrogen, useful microorganism immobilizing material for the purpose of reducing phosphorus,
Since it becomes a fishing reef and artificial seagrass, the shape is desirably an open shape like a petal. This microorganism in water, dissolved O _2, is for increasing the chance of contact between nutrients and the diameter of the cross section 3~12cm is preferred. If it is larger than 3 cm, the contact area increases, and if it is smaller than 12 cm, water easily penetrates into the inside. As the fiber composition, for example, a single or composite thermoplastic fiber such as polyolefin, polyester, polyamide, polyvinyl chloride, or polyvinylidene chloride is desirable. Non-thermoplastic fibers such as viscose rayon and cotton may be included for the purpose of imparting hydrophilicity or a carbon source. The structure (fineness) of the nonwoven fabric has an average fineness of 1
It is preferably 0 denier or more, and if the fineness is too small, clogging may occur. The apparent density of the nonwoven fabric before sealing is preferably 0.2 g / cm ³ or less from the viewpoint of clogging.
The nonwoven fabric may be a nonwoven fabric by fiber bonding or a nonwoven fabric by binder bonding, and may be subjected to a polymer treatment or an ion exchange treatment for increasing the amount of immobilized microorganisms. The number of layers is suitably 3 to 6 (the number of petals is 6 to 12), and the thickness of one sheet is preferably about 3 to 15 mm. Also,
In order to reduce the thickness of one petal, reduce the number of the petals, and open the petals evenly, as shown in FIG. 5, a thin, dense, wide non-woven fabric 4 and a thick, elastic, narrow non-woven fabric 5
Can be achieved by alternately stacking and sealing the center. When used as a scourer or abrasive, cushioning, (rebound resilience), and abrasion resistance (especially in a slit cross section) are required. As the shape, a structure in which the gap between the petals is not so open or a structure in which the petals are stuck together to form a mall is good. Further, the slit may be meandered to form a string of irregularities such as a gourd. As the fiber composition, polyamide, polyester, polyolefin, PVC, or the like is used, and a fiber having high rigidity is preferable. As the nonwoven fabric structure, it is preferable to use an adhesive in addition to the bonding with the heat-fused fiber in order to improve the wear resistance. The adhesive component (including the adhesive fiber) is preferably 30% or more, and the fineness varies depending on rough polishing and finish polishing, but is preferably from 0.1 denier to 100 denier. Further, an abrasive (eg, carborundum) is also used. It may be applied (adhered).
When used as a decoration for Christmas decorations, clothing (preferably sewing the seal, compressing and sewing), emeraki, accessories, etc., the tactile sensation is important. It is preferable that there is no gap. Fiber composition, polyamide, polyester, acrylic, polyolefin, rayon, cotton, etc. are used, as the structure of the non-woven fabric, 0.1 to 12 denier is fine, high crimp fiber, using latent crimped fiber It is good to have softness of volume and softness, and warmth.

[0013]

【Example】

Example 1 Weight 20 made of Chisso ES fiber (denier 20 denier)
0 g / m ² , thickness 8 mm, apparent density 0.025 g / c
Five heat-sealed nonwoven fabrics of m ³ are laminated and ultrasonically sealed at 8 cm intervals in the longitudinal direction. Next, 4 on each side of the seal
Slit vertically to cm width. In this way, a petal having a diameter of about 8 cm and a cross section of 10 petals is formed, the inner peripheral portion is in close contact, and the outer peripheral portion is open, respectively, to form a string-like nonwoven fabric. Cut this string-like non-woven fabric to 1m length,
It is effective when used as a biofilm purification carrier for river, sea, and industrial wastewater and a useful microorganism-immobilization carrier.

Example 2 A non-woven fabric was prepared by adhering a benzyl halide 4-vinylpyridine-styrene copolymer as a microorganism-adsorbing polymer to the non-woven fabric base used in Example 1.
As described above, a laminate obtained by laminating five sheets and then sealing and slitting is excellent in the ability to adsorb microorganisms and is useful as a carrier for immobilizing microorganisms.

Example 3 An acrylic adhesive was applied to a web of polyamide fiber having a fineness of 30 denier to prepare a nonwoven fabric having a fiber / binder ratio of 60/40, a basis weight of 350 g / m ² , and a thickness of 15 mm.
After stacking eight nonwoven fabrics and sealing them in the longitudinal direction using a high-frequency welder, slit them to a width of 5 cm around the seal portion. The cross-section of the laminated non-woven fabric spreads in a circle, and becomes a highly elastic string without any gap between the non-woven fabrics. This non-woven fabric is useful as a substitute for luffa, which is cut into 1-meter lengths and rubs the body, and as a scrub for bath cleaning when wound around hands.

[0016] Example 4 fineness 6 denier, basis weight 300 g / m ² to high crimp type core component polyethylene terephthalate and the sheath component is composed of core-sheath composite fibers of polybutylene terephthalate,
A non-woven fabric having a thickness of 25 mm is prepared. After laminating four non-woven fabrics, compressing them and forming 10 suture lines in the machine direction in the longitudinal direction at intervals of 6 cm, and slitting the middle between the suture lines, a molding having a cross-section diameter of about 6 cm is obtained. 10 long nonwoven fabrics can be made at the same time. This cord-like nonwoven fabric has a soft touch and rich cushioning properties, and is useful for decoration for Christmas and the like, cushioning materials for clothing, and malls for cold weather.

[0017]

According to the present invention, a three-dimensional cord-like nonwoven fabric having a petal-like long cross section with a large tensile strength can be easily formed, so that a material having many uses can be provided. Product development can be expected.

[Brief description of the drawings]

FIG. 1 is a diagram showing a state of a manufacturing process of a three-dimensional nonwoven fabric of the present invention.

FIG. 2 is a view showing the petals of the three-dimensional nonwoven fabric of the present invention.

FIG. 3 is a partial perspective view showing a columnar shape of the three-dimensional nonwoven fabric of the present invention.

FIG. 4 is a cross-sectional view of the three-dimensional nonwoven fabric of the present invention in which the distance from the joint to the cutting line is different on the left and right.

FIG. 5 is a cross-sectional view of the three-dimensional nonwoven fabric of the present invention in which nonwoven fabrics having different widths are laminated.

[Brief description of reference numerals]

The distance to the cutting line from the distance W ₂ junctions from 1 wide-rich wide nonwoven 5 thick elastic nonwoven fabric 2 linear junction 3 cutting line 4 dense narrower nonwoven W ₁ joint to the cutting line

Claims (3)

(57) [Claims] 1. A three-dimensional nonwoven fabric having a cross section in a shape having radial pleats and having a linear joint inside. 2. The three-dimensional nonwoven fabric according to claim 1, wherein a cross-sectional shape having radial folds is continuous in a longitudinal direction. 3. A non-woven fabric comprising one or a plurality of laminated non-woven fabrics,
A method for producing a three-dimensional nonwoven fabric, comprising forming a linear joint at an interval, and cutting between the linear joint and the linear joint.