JPH0137504B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a patterned nonwoven fabric used as general interior materials such as wall materials and floor materials, and vehicle interior materials.

<Prior art> Conventionally, as a method for attaching arbitrary patterns to non-woven fabrics, various patterns are applied by post-processing such as printing or embossing to non-woven fabrics formed from webs mixed with raw cotton of one or more colors. I found a way to add patterns.

There is also a method of patterning a non-woven fabric by needling a fiber sheet or fiber mass that has been previously slit or die-cut into a desired shape and integrating the fiber sheet or fiber mass into a non-woven fabric.

However, manufacturing a patterned nonwoven fabric by such a method requires a lot of effort, tends to produce defective products, and has the problem of high processing costs.

In order to solve this problem, a wrap is supplied to a carding device consisting of a plurality of rotating bodies having many protrusions on the surface, and the fibers are placed below the device. The fibers are transferred between each rotary body in the carding device in order to sequentially perform operations in which the undefinated fibers are dropped onto a moving conveyor, and the undefinated fibers are carded and defibrated while falling onto the conveyor. The carging conditions such as protrusions and gauges are set to actively make it difficult to increase the amount of fiber falling, and raw cotton, raw cotton,
Fiber groups such as laps and slivers of different types or colors,
By feeding fiber aggregates such as rovings and nets at the same time and continuously collecting the fallen fibers on the conveyor while carging, the fibers are well fixed to the main body of the web in the ground. A method has been proposed for forming a patterned nonwoven fabric by forming a patterned web having a substantially planar appearance and having patterned portions with hardly noticeable irregularities (for example, Japanese Patent Publication No. 13951/1983).

<Problems to be Solved by the Invention> However, in the patterned nonwoven fabric made by such a method, the pattern is formed by dropping the fiber aggregate for forming the pattern onto the main fibers forming the base. This makes it difficult to form delicate patterns such as geometric patterns, and it is difficult to obtain clear pattern outlines because the fiber aggregate and fiber main body for the pattern are carded and laminated as a multilayer body. There is a problem,
Furthermore, the lack of three-dimensionality in the pattern restricts the complexity and variety of the pattern.

<Means for Solving the Problems> The present invention has been made to solve the above problems, and the contents thereof will be explained below using FIGS. 1 and 2 corresponding to embodiments.

In this invention, an arbitrary pattern is created by supplying an arbitrary thread or filament-like material as a needle thread through a quilting process to a sheet-like material obtained by pre-needling a layered body made by laminating arbitrary short fibers. This is a patterned nonwoven fabric that is formed by sewing and then needling.

<Function> The present invention is constructed as described above, and any thread or thread-like material that will become the needle thread is quilted onto the pre-needled sheet material so as to form an arbitrary pattern. The pattern is fixed by sewing, and then the base material and the fiber aggregate of the pattern are intertwined by needling to form a nonwoven fabric, and this nonwoven fabric has a three-dimensional or It forms a two-dimensional pattern.

<Effects of the Invention> The patterned nonwoven fabric according to the present invention is as described above, and exhibits the following effects.

(a) Since patterns are created through quilting, complex and delicate patterns such as geometric patterns can be freely and easily formed.

(b) Since the web is not laminated on top of the pattern, the outline of the pattern can be clearly seen, and the color tone of the pattern can be expressed vividly.

(c) Due to the difference in elongation between the fibers of the thread or thread-like material that forms the pattern and the sheet-like material that forms the substrate, the pattern can be raised above the surface of the substrate through needling processing, creating a three-dimensional pattern. . Furthermore, it is possible to form a planar pattern by adjusting the needle depth.

(d) In the needling process using a fork needle, the yarn or filament-like material is entangled with the fork needle to a large extent, making it possible to further increase the fall of the pattern, and creating a pile-like surface with a rich three-dimensional effect. Patterned nonwoven fabrics can be formed.

(e) The pattern formed by the quilting process is
Since it is well fixed to the substrate by needling, it is possible to form a patterned nonwoven fabric with high wear resistance.

(f) By synchronously operating the quilting machine and the needle rocker, nonwoven fabrics with complex and diverse patterns can be manufactured with high efficiency.

The patterned nonwoven fabric thus obtained can be used for general interior purposes such as wall materials, carpets, etc., and for vehicle interior materials such as automobiles, and is expected to develop applications not found in conventional nonwoven fabrics. It is.

<Example> An example of the present invention will be described below based on the drawings.

FIG. 1 is a cross-sectional view of a patterned nonwoven fabric, where 1 is a patterned nonwoven fabric, 2 is a base of the nonwoven fabric, 3 is a thread or thread-like material (hereinafter sometimes simply referred to as thread-like material 3), and 4 is a bobbin thread. .

In the embodiment, the substrate 2 is made of short fiber raw material such as polypropylene or polyester, and is pre-needled to a desired thickness after being spread and laminated.

The thread-like material 3 used as the upper thread is made of, for example, a sliver, spun thread, or continuous thread having a required thread count, and the lower thread is made of a sliver, spun thread, continuous thread, or the like having a thread count equal to or less than that of the thread-like material 3.

Then, the thread-like material 3 and the bobbin thread 4 are quilted with the base body 2 in between, and are continuously entangled and sewn to the base body 2.

This needling pattern can be any arbitrary pattern, such as a diamond pattern as shown in FIG. 3A, a continuous circular pattern as shown in FIG. , a desired row can be formed over its entire width.

Selection of these patterns is easily made by adjusting the quilting machine.

After the quilting process, needling is performed with a felting needle at a predetermined needle depth to intertwine the base body 2, thread-like material 3, and bobbin thread 4.

At this time, the pattern is firmly fixed to one side of the base 2, and a clearly patterned nonwoven fabric 1 is formed.

Furthermore, FIG. 2 shows a sectional view of another embodiment.

This second embodiment is the same as the first embodiment except for the needling process, and is characterized by the needling process using a fork needle.

That is, the lower thread 4 of the quilted base body 2
Needling is performed from the side using fork needles aligned at the same needle depth to intertwine the base 2, the thread-like material 3, and the bobbin thread 4, and the thread-like material 3 of the base 2 is intertwined.
A pile part 5 is formed by making a pile out on the side.

At this time, the highly elongated filament 3 is extruded while being entangled with the head split portion at the tip of the fork needle, and a nonwoven fabric 1a having a pile with a desired pattern that is further raised than the pile portion 5 is formed. Note that even if the patterned nonwoven fabric 1 obtained in the first example is further subjected to needling processing using a fork needle,
Substantially the same effect as above can be obtained.

Note that the above-mentioned pattern is not limited to the illustrated example, and it is possible to form all quilting patterns that can be expressed by a quilting machine, such as a striped pattern and a zigzag pattern.

In addition, by performing a quilting process using a thread, thread-like material, or bobbin thread as a latent crimp thread and applying heat treatment, the patterned portion can be raised and a nonwoven fabric with a three-dimensional pattern can be formed. .

Furthermore, resin processing with latex or the like can be performed if necessary.

[Brief explanation of drawings]

FIG. 1 is a sectional view showing one embodiment of the patterned nonwoven fabric of the present invention, FIG. 2 is a sectional view showing another embodiment, and FIG. 3 is a plan view showing an example of the pattern. 2... Base body, 3... Filiform material, 5... Pile part.

Claims (1)

[Scope of Claims] 1. A sheet-like product obtained by pre-needling a layered product made by laminating arbitrary staple fibers, and then supplying an arbitrary thread or filament-like material as a needle thread through quilting processing. A patterned nonwoven fabric made by sewing a desired pattern onto it and then applying needling processing. 2. The patterned nonwoven fabric according to claim 1, wherein the needling process is performed by applying a pile from the lower thread side of the quilting using a fork needle.