JP6429563B2 - Needle punch device and needle punch method - Google Patents

Description

The present invention relates to a needle punching device and a needle punching method used when producing a bulky nonwoven fabric frequently used for car mats and civil engineering materials.

  As a means for obtaining a bulky nonwoven fabric, a needle punch method has been conventionally used. Along with this, the shape of the needle punch needle, the shape of the notch (hereinafter also referred to as “barb”) provided on the needle, the position of the barb, etc. affect the physical properties of the resulting nonwoven fabric, The influence on the design has been studied for a long time.

  In the needle punch device, punching is performed while the fiber web is advanced in the machine direction, that is, the longitudinal direction of the web. For this reason, the web proceeds with the needle penetrating the web for a short time. For this reason, the needle penetrating the web serves as an anchor, and the constituent fibers of the web are easily pulled in the direction opposite to the traveling direction. As a result, there is a problem that the strong balance of the web is lost, and the width-increasing phenomenon occurs. As countermeasures, studies have been made such as making the needle stroke into an elliptical motion, or penetrating the needle obliquely with respect to the web traveling direction.

  In general, in the needle punch method, when the barb provided on the needle punch needle penetrates the web, it engages with the fiber forming the web and repeatedly protrudes the fiber in the direction opposite to the needle entry side. However, the fibers are entangled three-dimensionally. For this reason, fibers that are present on the needle entry side and are not engaged with the needle are not entangled so much that they become fluff and floating yarn, causing problems. Moreover, since the entanglement direction is only one direction of the needle entry direction, the nonwoven fabric obtained thereby has a problem that it is easily separated into layers.

  In order to solve these problems, a method of performing needling from both sides of a web using a plurality of needle punch machines is generally employed (Patent Document 1). However, when manufacturing non-high quality non-woven fabrics, for example, civil engineering materials or some kind of base material, a plurality of needle punch machines are prepared and installed on these needle punch machines. Passing through is very uneconomical, and the resulting bulky nonwoven fabric often has excessive performance.

Japanese Patent Laid-Open No. 9-302564

  An object of the present invention is to solve the problems of needling only from one direction without introducing large equipment or the like, and needing only from one direction. .

In order to achieve this object, the needle punch device of the present invention comprises:
A needle punch device for performing a needle punch process on a fiber web traveling in a longitudinal direction,
It has only forward barbs that can penetrate the fiber webs in a three-dimensional manner by having a notch that can penetrate the fiber web and hook the constituent fibers of the fiber web when penetrating . A first needle punch needle is provided ;
By have a three-dimensionally inverse cutting hook capable of entangling the constituent fibers to each other by hooking the fibers constituting the fiber web when moving direction pullback after penetration of the insertion direction of the fiber web, configuration fibers A second needle punch needle with a reverse barb that can be entangled three-dimensionally ,
The second needle punch needle is characterized in that the reverse hooking portion is arranged toward the downstream side along the traveling direction of the fiber web.

  In the needle punch device of the present invention, it is preferable that the needle punch needle is disposed so that the reverse hooking portion is oriented within an angle range of ± 45 degrees with respect to the traveling direction of the fiber web. In the needle punch device of the present invention, it is preferable that the angle of the reverse punching portion of the needle punch needle is 70 degrees or more and less than 90 degrees, and the reverse punching portion of the needle punch needle is in the length direction of the needle. It is preferable that it is formed in the range of 3 mm or more and 10 mm or less from the needle tip.

The needle punch method of the present invention comprises:
When performing a needle punching process on the fiber web traveling in the longitudinal direction,
It has only forward barbs that can penetrate the fiber webs in a three-dimensional manner by having a notch that can penetrate the fiber web and hook the constituent fibers of the fiber web when penetrating . Using a first needle punch needle, and
By having a reverse hooking part that can hook the constituent fibers of the fiber web and move the constituent fibers three-dimensionally during movement in the pull-back direction after penetration in the insertion direction into the fiber web, Using a second needle punch needle with a reverse barb that can be entangled three-dimensionally,
At that time, the second needle punch needle is used with its reverse hooking portion directed downstream in the traveling direction of the fiber web.

  According to the needle punch device of the present invention, the reverse punching portion of the needle punch needle is arranged toward the downstream side along the traveling direction of the fiber web, so that the fiber hooked at the time of pulling back the needle travels the fiber web. Can be easily released after the confounding process.

  According to the needle punching method of the present invention, since the needle punch needle is used with its reverse hooking portion directed downstream in the traveling direction of the fiber web, the fibers caught when the needle is pulled back are used for the progress of the fiber web. Therefore, it can be easily released after the confounding process.

  That is, according to the present invention, it is possible to perform a pseudo needle punching process from both sides by reverse barb only by performing a needle punching process from one direction. For this reason, the subject which the needle punch process from the former one direction had easily can be solved, without introducing big equipment etc.

It is a figure which shows the needle punch needle | hook of embodiment of this invention. It is a figure which expands and shows the principal part of the needle punch needle | hook of FIG. It is a figure which shows the arrangement | positioning state of the needle punch needle | hook in the needle punch apparatus of embodiment of this invention. It is a figure which shows the arrangement | positioning state of the other needle punch needle | hook in the needle punch apparatus of embodiment of this invention. It is a figure which shows the arrangement | positioning range of the reverse hooking part of the needle punch needle | hook in the needle punch apparatus of embodiment of this invention.

  In the needle punch needle shown in FIG. 1, a shank 1, an intermediate blade 2, and a blade 3 are provided in order from the proximal end side of the needle. In the illustrated needle punch needle, the shank 1 and the intermediate blade 2 are formed in a circular cross section, and the blade 3 is formed in a triangular cross section. A crank 4 is formed at the base end of the shank 1. However, in the present invention, the type and material of the needle may be arbitrary and may be the same as those generally used. As the cross-sectional shape of the blade 3, a quadrilateral shape and other things can be adopted in addition to the triangular shape shown in the figure. A tip taper portion 5 is formed at the needle tip.

  The blade 3 is formed with a cut portion (barb). Specifically, as shown in FIG. 1, forward cut portions (forward barbs) 6 are formed at two points of the triangle vertices of the blade 3, and the other one of the vertices is reversed. Cut portions (reverse barbs) 7 are formed. 1 and 2, reference numeral 8 denotes a kick-up, which is formed in a sharp shape protruding from the triangular outline of the blade 3. It is 9 throats and is formed in the form of a recess provided close to the kick-up 8. The forward barb 6 is formed in the order of the throat 9 and the kick-up 8 from the tip side of the needle, and the throat 9 and the kick-up 8 are inclined toward the tip side of the needle, that is, the tip side of the blade 3. Is formed. On the other hand, the reverse barb 7 is formed in the order of the kick-up 8 and the throat 9 from the distal end side of the needle. These kick-up 8 and throat 9 are opposite to the proximal end side of the needle, that is, the distal end side of the blade 3. It is formed in a posture inclined toward the side.

  The reverse barb 7 will be described in detail with reference to FIG. Here, θ is a turning angle of the reverse barb 7 and means an opening angle of the kick-up 8 with respect to the center axis 10 of the needle, that is, the blade 3. For the reasons described later, the angle θ is 70 degrees or more and less than 90 degrees.

  In FIG. 2, 11 indicates the distance from the tip of the needle to the reverse barb 7, that is, the distance from the tip of the tapered portion 10 to the kick-up 8. This distance is preferably 3 mm or more and 10 mm or less for the reason described later.

  In the needle punch device according to the embodiment of the present invention, many needle punch needles shown in FIGS. 1 and 2 are used. The needle punch device is supplied with a strip-like long fiber web, and the needle punch needle is inserted into the fiber web at a high speed while the fiber web is advanced in the machine direction, that is, the longitudinal direction. . In that case, a needle punch needle having a forward barb 6 and a reverse barb 7 as shown in FIGS. 1 and 2 can be used, and the reverse barb 7 is directed downstream along the traveling direction of the fiber web. It is important that the needle punch needle is installed in the needle punch device so as to be in a state.

  FIG. 3 shows a state in which a needle punching process is performed on the fiber web 12 using a needle punch needle having a triangular cross-sectional shape of the blade 3 in the needle punch device. An arrow 13 indicates the traveling direction of the fiber web 12. As shown in the figure, the reverse barb 7 of the needle punch needle is directed to the downstream side along the traveling direction 13 of the fiber web 12.

  FIG. 4 illustrates a case where a needle punch needle having a blade 3 having a rectangular cross section, that is, a plate-like blade 3 is used. The needle punch needle is used in a posture in which the long side of the rectangle having a cross-sectional shape is aligned with the traveling direction 13 of the fiber web 12. The reverse barb 7 is formed on the downstream side in the traveling direction 13 of the fiber web 12, that is, on the short side of the rectangular shape of the cross section of the plate-like blade 3.

  In the needle punching device, when performing the needle punching process, the fiber web 12 is advanced in the horizontal direction, and the needle punch needle is inserted into the fiber web 12 from the upper side of the advancing fiber web 12 downward. To penetrate. At this time, as shown in FIG. 1A, the forward barb 6 hooks the constituent fibers 14 of the fiber web 12 and moves them in the thickness direction of the fiber web 12, so that the three-dimensional entanglement of the constituent fibers 14 is performed. Is done.

  Thereafter, the needle punch needle is pulled back. At this time, as shown in FIG. 1 (b), the reverse barb 7 hooks the constituent fibers 14 and moves them in the thickness direction of the fiber web 12, whereby the constituent fibers 14 are entangled three-dimensionally. In this way, not only when the needle punch needle moves in the insertion direction but also when it moves in the pull-back direction, the three-dimensional entanglement between the constituent fibers 14 is performed. Also in the portion of the fiber web 12 on the proximal end side of the needle punch needle, the constituent fibers are entangled well.

  In the reverse barb 7, when the needle punch needle is pulled out from the fiber web 12, it is necessary that the constituent fibers 14 that are hooked on the reverse barb 7 quickly come off with the progress of the fiber web 12. is there.

  In this case, in the needle punch device, since the reverse barb 7 is directed to the downstream side along the traveling direction 13 of the fiber web 12 as described above, the constituent fibers 14 that are hooked on the reverse barb 7 are: It can be easily detached as the fiber web 12 advances.

  Specifically, as shown in FIG. 5, the constituent fibers 14 are detached by disposing the reverse barb 7 in the range 16 and 16 of ± 45 degrees from the axis 15 in the traveling direction 13 of the fiber web 12 in plan view. The effect is good. When the ranges 16 and 16 are ± 30 degrees, this effect can be exhibited better. In a range other than the above, i.e., when it is difficult to say that the reverse barb 7 is oriented in the traveling direction 13 of the fiber web 12, the constituent fibers 14 are less likely to come off as the fiber web 12 travels. It becomes easy to be in the state where the constituent fibers 14 are caught on the reverse barb 7. For this reason, in extreme cases, the fiber web 12 may be pulled greatly in the direction opposite to the traveling direction thereof, the constituent fibers 14 may be cut, or the needle punch needle may be broken. Absent.

  Further, in the needle punch device of the present invention, a needle having a reverse barb 7 with a cut angle θ of 70 degrees or more and less than 90 degrees as shown in FIGS. 1 and 2, that is, a needle with the reverse barb greatly opened outward is used. Then, the constituent fiber 14 caught on the reverse barb 7 can be more easily detached. When the cutting angle θ is less than 70 degrees, the degree of catching of the constituent fibers 14 on the reverse barb 7 is increased, and the constituent fibers 14 are quickly released when the needle punch needle is extracted from the fiber web 12. It tends to be difficult to disengage from the needle punch needle. On the other hand, if the angle of cut θ is 90 degrees or more, the constituent fibers 14 are hardly caught on the reverse barb 7 in the first place or are not caught, and it is difficult to achieve the desired effect. Or, there is a risk that the result is significantly different from the target.

  As described above, the distance 11 from the tip of the needle shown in FIG. 2 to the reverse barb 7 is preferably 3 mm or more and 10 mm or less. In the case of the forward barb 6, the insertion depth of the needle and the formation position of the barb are one of the factors that determine the extrusion length of the constituent fibers 14, that is, the degree of entanglement. On the other hand, in the case of the reverse barb 7, the surface of the stripper plate from which the needle punch needle protrudes toward the fiber web in the needle punch device and the formation position of the reverse barb 7 on the needle punch needle are configured from the fiber web 12. This is one of the factors that determine the length of the fibers 14 to be drawn, that is, the degree of entanglement. However, if the constituent fibers 14 are pulled out from the surface of the fiber web 12 too much, it may cause generation of cracks. However, this pull-out length cannot be less than the distance 11 from the needle tip to the reverse barb 7 shown in FIG. Therefore, this distance is preferably as short as possible. However, the vicinity of the tip of the needle punch needle is tapered and thin, and the rigidity and strength are not high. Therefore, if the reverse barb 7 is provided on the tip end side of the needle too much, the needle punch needle is likely to break or bend due to an increase in the needle load due to the constituent fibers 14 being caught. For this reason, as described above, the distance 11 from the tip of the needle punch needle to the reverse barb 7 is preferably 3 mm or more and 10 mm or less.

  The needle punch needle used in the needle punch device of the present invention may be one in which the forward barb 6 and the reverse barb 7 are formed on one needle as shown in FIG. Only the reverse barb 7 may be formed on the needle. In the case of a needle in which only the reverse barb 7 is formed, the number of barbs is arbitrary and may be one or more. However, a needle in which the forward barb 6 and the reverse barb 7 are formed can be preferably used. This is because the confounding process in the forward direction and the confounding process in the reverse direction can be performed at a time in one needle reciprocation process.

  However, in the case of the needle having both the forward barb 6 and the reverse barb 7, the distance between the surface of the stripper plate and the reverse barb 7 of the needle punch needle as described above, that is, the reverse barb 7 as compared with the needle having only the forward barb. It is necessary to change the length of the constituent fibers 14 drawn from the non-woven web 12 and the needle depth during needle punching. For this reason, there is a possibility that a situation in which the function of the forward barb 6 cannot be sufficiently drawn out, and examination is necessary.

  When the needle having the forward barb 6 and the reverse barb 7 is not used, that is, when the needle having only the reverse barb and the needle having only the forward barb are used, the needle by the needle having only the reverse barb is used. After or before the punching process, these needles may be arranged so as to perform the needle punching process with a needle having only a forward barb. Alternatively, needles with only reverse barbs and needles with only forward barbs are arranged alternately along the direction of fiber web travel, and needle punching with needles with only reverse barbs and only forward barbs are provided. The needle punching with a needle may be repeated.

  In detail, needle punching may be performed by installing a reverse barb needle or a normal barb needle separately for each needle board generally installed in the needle punching device along the traveling direction of the fiber web. A reverse barb needle and a normal barb needle may be mixed in a single needle board. The order of needle punching by reverse barb and needle punching by forward barb is not particularly limited. For example, when needle punching is applied to a fiber web that has been temporarily bonded between fibers, there is a problem that the needle punching needle receives a large impact from the web at the initial stage of needle punching, and the needle easily breaks. It is preferable to perform needle punching with a reverse barb needle after needle punching with a needle.

(Example 1)
A reverse barb needle punch needle provided with a reverse barb having a distance of 6 mm from the tip of the needle to the reverse barb and an angle of cut of 85 degrees was prepared on a needle having an ordinary triangular cross section. This needle was installed on the needle board so that the direction of the reverse barb was 0 degrees with respect to the web traveling direction. This needle board was attached to the needle punch machine, and the needle punch machine was set so that the distance between the surface of the stripper plate and the reverse barb was 5 mm. Using this needle punching machine, a needle punching process was performed on a fiber web having a basis weight of 100 g having a continuous fiber of polyethylene terephthalate as a constituent fiber under the conditions of a needle depth of 10 mm and a punch number of 10 p / cm ² . Subsequently, using a normal needle punch needle R-36 # (manufactured by Foster Co., Ltd.) having only forward barbs, needle punching was performed under the conditions of a needle depth of 10 mm and a punch number of 40 p / cm ² .

(Example 2)
Instead of the reverse barb needle punch needle of the first embodiment, a needle having a triangular cross section similar to that of the first embodiment is provided with a reverse barb having a distance from the tip of the needle to the reverse barb of 3 mm and a cutting angle of 85 degrees. In addition, a reverse barb needle punch needle was prepared. And the needle punch process similar to Example 1 was performed. The treatment with needles with only forward barbs was carried out as well.

(Comparative Example 1)
Needle punch processing using a needle with a reverse barb was not performed, but only processing with a needle punch needle having only a forward barb was performed under the conditions of a needle depth of 10 mm and a punch number of 50 p / cm ² .

  The peeling state of the nonwoven fabric obtained in Examples 1-2 and Comparative Example 1 and the state of fluff were evaluated.

  As for the peeled state, “×” indicates that it was easily peeled off, “△” indicates that the nonwoven fabric shape was largely changed although peeling did not occur, and “◯” indicates that peeling was not clearly achieved. A stage evaluation was performed.

  About the state of the fluff, the surface when a 50 mm long adhesive tape (Nitto Denko “Craft Tape No. 712 38 mm width”) is applied to the surface of the obtained nonwoven fabric on the needle punch needle entry side, and then peeled off The condition was observed. The evaluation was made in two stages, with “×” indicating that a large number of fibers floated on the surface of the nonwoven fabric, and “◯” indicating that the number of fibers floating on the surface of the nonwoven fabric was disordered but “○”.

  As a result, for Examples 1 and 2, the imbalance was not increased when pulled in the vertical and horizontal directions of the obtained nonwoven fabric, and good peeling and surface fluff conditions were obtained. All were “◯”.

  In Comparative Example 1, although the shape of the obtained non-woven fabric was good, when evaluated, a large number of fluff on the surface was generated, and the shape changed greatly in the peeling evaluation. “△”.

Claims (5)

A needle punch device for performing a needle punch process on a fiber web traveling in a longitudinal direction,
It has only forward barbs that can penetrate the fiber webs in a three-dimensional manner by having a notch that can penetrate the fiber web and hook the constituent fibers of the fiber web when penetrating . A first needle punch needle is provided ;
By have a three-dimensionally inverse cutting hook capable of entangling the constituent fibers to each other by hooking the fibers constituting the fiber web when moving direction pullback after penetration of the insertion direction of the fiber web, configuration fibers A second needle punch needle with a reverse barb that can be entangled three-dimensionally ,
The needle punching device, wherein the second needle punch needle is disposed with its reverse hooking portion facing downstream along the traveling direction of the fiber web. 2. The needle punch device according to claim 1, wherein the second needle punch needle is disposed so that the reverse hooking portion is within an angle range of ± 45 degrees with respect to the traveling direction of the fiber web. 3. The needle punch device according to claim 1, wherein the second needle punch needle has a reverse angle of 70 ° or more and less than 90 °. Second needle punching needles, inverse Unfinished section, one of the needle along the length are formed within a range of 10mm 3mm or more than the needle tip from claim 1, wherein up to 3 The needle punch device according to claim 1. When performing a needle punching process on the fiber web traveling in the longitudinal direction,
It has only forward barbs that can penetrate the fiber webs in a three-dimensional manner by having a notch that can penetrate the fiber web and hook the constituent fibers of the fiber web when penetrating . Using a first needle punch needle, and
By having a reverse hooking part that can hook the constituent fibers of the fiber web and move the constituent fibers three-dimensionally during movement in the pull-back direction after penetration in the insertion direction into the fiber web, Using a second needle punch needle with a reverse barb that can be entangled three-dimensionally,
At this time, the needle punching method is characterized in that the second needle punch needle is used with its reverse cut portion directed toward the downstream side along the traveling direction of the fiber web.

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