JPH0655987B2 - Bulky nonwoven fabric and method for producing the same - Google Patents

Description

The present invention relates to a bulky nonwoven fabric and a method for producing the same. More specifically, the present invention relates to a non-woven fabric having a two-layer structure comprising a surface non-woven fabric having a large number of loops formed on the surface thereof and a bottom non-woven fabric which restrains the loops to maintain the shape of a bulky non-woven fabric, and a manufacturing method thereof.

<Prior Art> Various kinds of cloth are known as a cloth having a loop on the surface. That is, various types of carpets and moquettes formed by knitting and weaving, tufted carpets, etc. correspond to these and are widely used. However, all of them are made of yarn, and are usually packed on the back side, which causes a problem that the manufacturing cost becomes high and the weight becomes heavy.

Various methods have been proposed for producing a fabric having these loops at a low cost and in large quantities. For example, a stitching method dry non-woven fabric formed by sewing a fiber web with a thread by a sewing machine or a knitting mechanism has bulkiness, but the fibers easily come off, the abrasion resistance is poor, and the needle holes are conspicuous. There is a problem that it is difficult to secure it.

On the other hand, a shrinkable fiber is used as the bottom nonwoven fabric, and the surface layer is entangled by laminating it with a normal shrinkable long-fiber nonwoven fabric. The non-woven fabric having the above-mentioned structure is disclosed in Japanese Patent Application No. 58-118254 filed under the name of "non-woven fabric" on July 1, 1983 by the same applicant as this application.
This nonwoven fabric has pile ridges formed on its surface, but the shrinkable fibers forming the bottom nonwoven fabric generally have a drawback that they are easily deteriorated by heat, and thus the ridged bulky nonwoven fabric formed therefor. It has a problem that its durability in use is weak. This is because, generally, when synthetic fibers are produced under the condition that heat shrinkage is imparted, the fibers tend to have a sharp decrease in strength during the subsequent heat treatment.

<Problems to be Solved by the Invention> The present invention solves the problems of conventionally known fabrics with loops, has a three-dimensional appearance and is bulky, does not come out of fibers in a loop state, and has durability during use. It is an object of the present invention to provide an excellent bulky non-woven fabric and a method for producing the same.

<Means for Solving the Problems> The inventors of the present invention have conducted extensive studies to solve the above-mentioned problems, and as a result, the bottom nonwoven fabric was provided with a special polyethylene terephthalate fiber having large heat shrinkability and improved thermal deterioration. They have found that the above-mentioned problems can be solved by using them, and arrived at the present invention. That is, an object of the present invention is a bulky non-woven fabric having a double structure consisting of a surface non-woven fabric and a bottom non-woven fabric, in which the fibers forming the surface non-woven fabric are partially physically entangled with the bottom non-woven fabric and the entanglement. Consisting of non-entangled parts that form a loop projecting upward in an arc shape with the part, whereby the surface of the bulky nonwoven fabric is provided with a large number of loops composed of a plurality of fibers, The fibers forming the bottom nonwoven fabric have a circular cross section with a radius R, and the average refractive index at the center thereof is n ||
(0), assuming that the average refractive index in the portion at a distance of 0.8R from the center is n || (0.8), 1.60≤n | (0) ≤1.67 and {n | (0.8) -n | (0)} ≥5 It is achieved by a bulky nonwoven fabric characterized by being polyethylene terephthalate continuous fibers satisfying × 10 ^-3 .

The manufacturing method for manufacturing the bulky nonwoven fabric according to the present invention comprises the following steps.

(a) A step of producing a web or a dry non-woven fabric made of arbitrary fibers for a surface non-woven fabric; (b) Elongation at break of 100% or more, boiling water shrinkage of 5% or more, and its constituent fiber cross section has a circular cross section with a radius R. Then, if the average refractive index of the central part is n || (0) and the average refractive index in the portion of 0.8R from the center is n || (0.8), then n ||
(0) ≦ 1.64 and {n | (0.8) −n | (0)} ≧ 5
A step of producing a nonwoven fabric comprising polyethylene terephthalate continuous fibers satisfying × 10 ^-3 as a bottom nonwoven fabric; (c) a step of laminating a web or a dry nonwoven fabric produced as the surface nonwoven fabric and the bottom nonwoven fabric; (d) Physically interlacing the fibers constituting the laminated web or dry nonwoven fabric with the fibers constituting the bottom nonwoven fabric; (e) the laminated nonwoven fabric after the physical entanglement is at 80 ° C to 150 ° C.
Shrink finishing step comprising the step of shrinking under heating.

The physical entanglement step may be performed only by needle punching over the entire surface of the laminated non-woven fabric, and further may be performed by adding an arbitrary shape, that is, dot-shaped, broken-line shaped, or linear partial thermocompression bonding. . By adding the partial thermocompression bonding in advance, a pattern corresponding to the partial thermocompression bonding can be formed on the bulky nonwoven fabric.

It is preferable to perform the widening heat setting after the laminated nonwoven fabric is thermally shrunk in the shrink finishing step. Further, it is more preferable to emboss from the bottom side in order to further improve the dimensional stability of the bulky nonwoven fabric produced.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings showing examples of the bulky nonwoven fabric of the present invention.

The bulky nonwoven fabric 1 of one embodiment of the present invention shown in FIG. 1 comprises a surface nonwoven fabric 10 and a bottom nonwoven fabric 20. As shown in FIG. 2 which is a longitudinal sectional view of the nonwoven fabric 1 of FIG. The fibers forming the non-woven fabric 10 are partially the bottom non-woven fabric 20.
The entangled portion 12 that penetrates into the inside to entangle with the fibers forming the bottom nonwoven fabric 20 and the non-entangled portion 11 that protrudes upward in an arc shape between adjacent entangled portions 12 to form a loop. .

The surface non-woven fabric 10 may be either a long fiber non-woven fabric or a short fiber non-woven fabric, and the fiber used is a fiber having a low heat shrinkage, for example, a heat shrinkage of 10% at 150 ° C. for 1 min.
The following fibers are polyethylene terephthalate fibers,
Fibers such as polyamide fibers, polyacrylonitrile fibers, synthetic fibers such as polyolefin fibers, recycled fibers such as viscose rayon, and natural fibers such as cotton wool may be arbitrarily selected and used according to the end use.

When a short fiber non-woven fabric is used as the surface non-woven fabric, each short fiber constituting the surface non-woven fabric is at least 1 in the short fiber.
The places need to be physically entangled as if they were entangled with the fibers in the bottom nonwoven fabric. In addition, the term "loop" in the present specification is defined to include a state in which short fibers forming a surface non-woven fabric form a loop, but the ends thereof are fluffy.

The fibers 21 forming the bottom nonwoven fabric 20 and in which the fibers in the surface nonwoven fabric 10 are entangled are polyethylene terephthalate long fibers having special physical properties, and the fibers have a circular cross section with a radius R, and the average of the center portions thereof. Refractive index is n
(0), assuming that the average refractive index in a portion at a distance of 0.8R from the center is n || (0.8), 1.60≤n | (0) ≤1.67 and {n | (0.8) -n | ( 0)} ≧ 5 × 10 ⁻³ . Regarding polyethylene terephthalate fiber (hereinafter referred to as PE long fiber after processing) having such special physical properties, the same applicant as the present application, March 1, 1984
It is disclosed in detail in Japanese Patent Application No. 59-50185 filed as "Nonwoven fabric having high elongation without heat shrinkage" on 7th. The polyethylene terephthalate fiber having this special property, that is, the PE long fiber after processing, was processed by the same applicant as "nonwoven sheet having high elongation with improved heat deterioration" on March 17, 1984. Japanese Patent Application No. 59-50184 filed as "Japanese Patent Application No. 59-50184", "elongation at break 100% or more, boiling water shrinkage 5% or more, fiber cross section has a circular cross section with radius R, and the average refractive index of the central portion thereof. Is n ‖ (0), and the average refractive index in the portion 0.8R from the center is n ‖ (0.8), then n ‖ (0) ≤ 1.64 and {n ‖
(0.8) -n | (0)} ≧ 5 × 10 ⁻³ “Polyethylene terephthalate fiber” (hereinafter referred to as “raw PE long fiber” for bulky nonwoven of the present invention) ”is obtained by heat treatment. It is a fiber.

The raw PE filaments are 5% or more by boiling water, usually 50%, as disclosed in Japanese Patent Application No. 59-50184.
It has the property of shrinking to some extent and is excellent in heat deterioration resistance. This heat deterioration resistance is not affected by heat treatment, and has excellent heat deterioration resistance even after shrinking by about 50% to form PE long fibers after processing.

Since the fibers constituting the bottom non-woven fabric of the bulky non-woven fabric according to the present invention are the above-mentioned processed PE fibers, as will be easily understood in the description of the method for producing the bulky non-woven fabric according to the present invention described in detail later. The PE fibers after the processing reliably grasp the entangled portion of the fibers forming the surface non-woven fabric.

3 and 4 show another embodiment of the bulky nonwoven fabric according to the present invention. 3 is a perspective view similar to FIG. 1, and FIG. 4 is a vertical sectional view similar to FIG. The bulky non-woven fabric 2 of the embodiment shown in FIGS. 3 and 4 is characterized in that the bottom non-woven fabric 20 is provided with a recess 30 having an arbitrary shape. By appropriately arranging the recesses 30, a pattern corresponding to the recesses 30 can be formed on the surface of the bulky nonwoven fabric 2. For example, when the lattice-shaped concave portions 30 are formed, a lattice pattern is formed on the surface of the bulky nonwoven fabric 2. In addition, this partial thermocompression bonding part has a surface nonwoven fabric 10
Since the loop-shaped fibers are more reliably fixed, the abrasion resistance is further improved and the dimensional stability of the bulky nonwoven fabric itself is further improved.

The bulkiness of the obtained bulky nonwoven fabric improves as the difference in heat shrinkage between the fibers in the surface nonwoven fabric and the fibers in the bottom nonwoven fabric increases. The difference is preferably 20% or more in order to obtain good bulkiness. The fineness of the fibers used may be selected within the range of 1d to 30d. In particular, in order to use the bulky nonwoven fabric of the present invention as a rug, it is preferable to use thick denier fibers in consideration of the loop waist and abrasion resistance. Next, the basis weight of the non-woven fabric may be selected in the range of 10 to 500 g / m ² depending on the intended use. The bulkiness is changed by changing the areal weight of the surface nonwoven fabric and the bottom nonwoven fabric, and the bulkiness is improved by making the basis weight of the bottom nonwoven fabric relatively large.

The bulky non-woven fabric according to the present invention is generally produced by dyeing the surface non-woven fabric and the bottom non-woven fabric respectively. However, when polyethylene terephthalate fibers are used as the surface non-woven fibers, it is possible to add color by post-dyeing. Further, the bulky nonwoven fabric according to the present invention may be used after being printed with a desired pattern on the surface thereof.

Next, a method for manufacturing the bulky nonwoven fabric according to the present invention will be described.

First, a web made of arbitrary fibers or a dry spun nonwoven fabric or a spun-pond long fiber nonwoven fabric obtained by subjecting the web to a slight needle punching process is prepared. On the other hand, a nonwoven fabric made of the above-mentioned raw PE filaments is prepared. Regarding the manufacturing method of this non-woven fabric, the above-mentioned Japanese Patent Application No. 59-50184.
No detailed description is given here. The two non-woven fabrics are laminated and the fibers in the surface non-woven fabric are entangled with the long fibers in the bottom non-woven fabric using a felt punch or a fork needle using a needle punch machine. Number of needle punches is 30 to 3
It may be selected at about 00 times / cm ² according to the intended use. If the number of needle punches is small, the entanglement density becomes coarse and large loops are formed, but on the other hand, the fibers in the surface non-woven fabric are easily removed.

When manufacturing a bulky non-woven fabric having recesses as shown in FIGS. 3 and 4, a temperature of 90 ° C. to 150 ° C.,
Embossing is performed at a pressure of 10 to 50 kg / cm ² . This embossing is performed from at least the surface non-woven fabric side, and may be performed from both sides. As the embossed pattern, any pattern such as a rectangular perforated pattern or a continuous linear lattice pattern may be used.
The area ratio of partial thermocompression bonding by this embossing is 3 ~
40% is preferable.

The laminated nonwoven fabric or the embossed nonwoven fabric is heat-shrinked in a free state at a temperature of 80 ° C. to 150 ° C. for about 1 minute in principle. The heat source may be hot water, steam or hot air. As the processing machine, various dyeing machines, short loop dryers, or teleters may be used while actively controlling the width. The bulky nonwoven fabric of the present invention is obtained by this heat shrinking process.

However, the following processing may be added to the bulky nonwoven fabric after the heat shrinkage.

Using a tenter or the like at a temperature of 150 ° C. to 180 ° C., widening and stretching of 2 to 10% in the vertical and horizontal directions is performed to flatten the bulky nonwoven fabric.

An embossing roll is arranged on the bottom nonwoven fabric side and a smoothing roll is arranged on the front side nonwoven fabric side, and the gap is set to 50% to 70% of the thickness of the bulky nonwoven fabric to allow the bulky nonwoven fabric to pass through. In this case, since the temperature of the embossing roll is set to 150 ° C. to 200 ° C. and the smoothing roll is set to 100 ° C. or less, the bottom nonwoven fabric side is embossed, and as a result, the dimensional stability of the bulky nonwoven fabric is further improved. .

In addition, bulky non-woven fabrics can be electrically and water repellent if necessary.
Surface resin processing or the like may be performed for additional performance improvement.

The bulky non-woven fabric of the present invention uses two types of non-woven fabrics having different heat shrinkages as described above to generate a plurality of loop fibers on the surface by heat shrinkage, and the bottom non-woven fabric contains the above-mentioned raw PE filaments. Since it is used, it is possible to obtain a bulky non-woven fabric which has a three-dimensional effect, is bulky and soft, does not allow the fibers in a loop state to come off, and has excellent durability during use. Furthermore, since the bulky nonwoven fabric according to the present invention uses the nonwoven fabric made of the above-mentioned raw PE filaments as the bottom nonwoven fabric, it can be molded. Therefore, the bulky nonwoven fabric of the present invention is an interior material for automobiles,
It has excellent performance when used in furniture cloths, carpets and mats, bedding materials, etc.

<Examples> Specific configurations and manufacturing methods of several examples of the bulky nonwoven fabric of the present invention will be shown below, and the physical properties of the non-woven fabric will be compared with those of the counterpart product.

The definitions and measuring methods of various physical properties used for comparison in physical properties are shown below.

◎ Metsuke Take a test piece of 20 cm x 20 cm, weigh it, and convert it into a unit weight.

◎ Thickness: At least 3 using a dial gauge with a load of 100 g / m ^2.
Measure at more than one point and express the average value.

◎ Loftness Obtain the volume per unit weight from the values of the above areal weight and thickness,
Expressed as bulkiness.

◎ Fracture strength and elongation Measured with an Auto Graph DSS-2000 universal tensile tester manufactured by Shimadzu Corporation at a grasping length of 10 cm and a tensile speed of 20 cm / min.
The sample is 3 cm x 20 cm, and each 3 points in the vertical and horizontal directions.
Expressed as an average value.

◎ Hand feeling The bending resistance is determined by the 45 ° cantilever method and used as the evaluation value of the hand feeling.

◎ Abrasion resistance A test piece measuring 20 cm in length and 3 cm in width was rubbed 100 times with a friction tester type II (Gakushin type) under a load of 500 g, and then the appearance change of the test piece was checked according to the following criteria. It was judged and used as a guide for wear resistance.

(Judgment Criteria) Class A: No fuzz at all.

Class B: Some fluff, but not noticeable.

Class C: Conspicuous fuzz.

◎ Cushioning property Expressed by compression rate and compression elastic recovery rate according to JIS-L-1096. That is, a sample of about 5 cm square is made, three sheets are piled up and the thickness t ₀ is measured at an initial load of 50 g / cm ² , then a load of 300 g / cm ² is applied and left for 1 minute, and the thickness at this time is measured t ₁ And Measure the thickness at an initial load of 50 g / cm ² after leaving for 1 minute after unloading t ₂
And The compressive modulus and compressive elastic modulus are calculated by the following formulas.

Manufacturing conditions of Example-1 Spunbond nonwoven fabric made of ordinary polyethylene terephthalate filaments as a surface nonwoven fabric (fineness 2 ^d , basis weight 15)
g / m ² . Using a spunbonded nonwoven fabric (fineness 3 ^d , basis weight 50 g / m ² , single yarn shrinkage 46%) composed of the above-mentioned raw PE filaments as the bottom nonwoven fabric, these two nonwoven fabrics are used. Layered and needle punched (Needle type:
The fibers are entangled with a felt needle # 40 regular barb, depth 12 mm, number of times 100 times / cm ² . The non-woven fabric after needle punching is dried with a short loop dryer (temperature 15
The bulky nonwoven fabric of Example 1 is obtained by widening the vertical and horizontal directions by 5% at 0 ° C. for 1 minute).

Manufacturing conditions of Example-2 The needle punched nonwoven fabric made under the same manufacturing conditions as in Example-1 is temporarily embossed with a lattice pattern (pitch 10 mm, width 1 mm, thermocompression bonding area ratio 19%) embossing roll. (Upper roll temperature 110 ° C, lower roll temperature 70 ° C, pressure 20 kg / cm ² ). After that, heat shrinking and widening heat setting are performed under the same conditions as in Example-1 to obtain the bulky nonwoven fabric of Example-2.

Comparative Example-1 and Comparative Example-2 As the nonwoven fabric of Comparative Example-1, spunbonded nonwoven fabric (fineness 2 ^d ,
Using a basis weight of 100 g / m ² and a single yarn shrinkage rate of 4%), Comparative Example-2
As the non-woven fabric, the non-woven fabric after the needle punching process of Example 1 was used.

Table 1 shows the results of evaluation of physical properties of Examples-1 and 2 and Comparative Examples-1 and 2.

As shown in Table 1, the bulky nonwoven fabrics of Examples 1 and 2 according to the present invention have a soft texture, a high bulkiness, and a good abrasion resistance. The loop shape on the surface has a cushioning property, and the loop is compressed by weighting (compression rate 60%), but the compression elastic recovery rate is 90% or more, and almost the original thickness is recovered. In addition, the texture has a soft texture despite the heat shrinkage, and the rigidity does not change much even if temporary embossing is performed. The abrasion resistance is also good, because the bottom nonwoven fabric shrinks and the fibers in the surface nonwoven fabric are tightly entangled and integrated with the bottom nonwoven fabric. In the bulky non-woven fabric of Example 2 which has been temporarily embossed, a lattice pattern is generated on the surface, and the number of fixing parts of the fibers in the surface non-woven fabric to the bottom non-woven fabric is increased by partial thermocompression bonding, and the loop shape of the surface is Less fluffing.

The non-woven fabrics of Examples 1 and 2 are characterized by a high elongation at break, and thus can be molded.

The non-woven fabric of Comparative Example-1 is bulky and has a feeling in Example-1.
And inferior to 2, the non-woven fabric of Comparative Example-2 has a cushioning property,
Inferior to Examples 1 and 2 in wear resistance.

Manufacturing conditions of Example-3 A spunbonded nonwoven fabric composed of ordinary polyethylene terephthalate filaments as a surface nonwoven fabric (fineness 10 ^d , basis weight 3
5 g / m ² . Using a single yarn shrinkage rate of 6%), a spunbonded non-woven fabric (fineness 1) made of the raw PE filaments as the bottom non-woven fabric
6 ^d , basis weight 100 g / m ² , single yarn shrinkage rate 48%), these two nonwoven fabrics are laminated and needle punched (needle type: felt needle 36 regular barb, depth 15 mm, 150 times / cm) ² ) Entangle the fibers. The nonwoven fabric after needle punching is subjected to heat shrinkage and widening heat setting under the same conditions as in Example 1 above, to obtain the bulky nonwoven fabric of Example-3.

Manufacturing Conditions of Example-4 A needle punched non-woven fabric made under the same manufacturing conditions as in Example-3 was perforated (pitch 10 mm, width 1 mm,
Temporary embossing with thermocompression bonding area ratio 7%) (upper roll temperature 120 ° C, lower roll temperature 80 ° C, pressure 30 kg / cm ² ). After that, heat shrinking and widening heat setting are performed under the same conditions as in Example-3 to obtain the bulky nonwoven fabric of Example-4.

Manufacturing Conditions of Example-5 The non-woven fabric of Example-4 was further smoothed on the surface of the floor using a pair of smooth rolls (upper roll temperature 190 ° C., lower roll temperature 80 ° C., roll gap 1.0 mm, floor part (Contacting the upper roll) to obtain the bulky nonwoven fabric of Example-5.

Comparative Example-3 As the non-woven fabric of Comparative Example-3, the non-woven fabric after the needle punching of the above-mentioned Example-3 was used.

Table 2 shows the physical property evaluation results of Examples-3, 4 and 5 and Comparative Example-3.

As shown in Table 2, the bulky nonwoven fabrics according to the present invention of Examples-3, 4 and 5 are the same as those of Example-1 shown in Table 1.
It has the same excellent physical properties as the bulky nonwoven fabrics of No. 2 and 2. Further, although not shown in Table 2, since the constituent long fibers of the surface non-woven fabric have a large fineness, the loop is elastic and the abrasion resistance is further improved. In the bulky non-woven fabric of Example-4, the fibers constituting the surface non-woven fabric are thermocompression-bonded to the bottom non-woven fabric in spots, so that the bulky non-woven fabric has an appearance like a loop pile tufted carpet, giving an excellent design effect. Has been. In the bulky nonwoven fabric of Example-5, the bottom surface was smoothed and the dimensional stability was further improved.

The nonwoven fabric of Comparative Example-3 is inferior to Examples-3, 4 and 5 in cushioning property and abrasion resistance.

Needle punch nonwoven fabric (fineness ^{3 d} × ^51mm50% made of nylon short fibers as manufacturing conditions the surface nonwoven fabric of Example -6, fineness ^{7 d} × 51 mm
50%, basis weight 200 g / m ² . Using a single yarn shrinkage rate of 5%), a spunbonded nonwoven fabric composed of the above-mentioned raw PE filaments as the bottom nonwoven fabric (fineness 3 ^d , basis weight 100 g / m ² , single yarn shrinkage rate 36)
%) To laminate these two non-woven fabrics and perform needle punching (needle type: felt needle # 40 regular barb,
The fibers are entangled at a depth of 15 mm and the number of times is 200 times / cm ² . Then, using a tenter, both vertical and horizontal 20%
The bulky nonwoven fabric of Example 6 is obtained by shrinking at an overfeed rate of and heat setting.

Comparative Example-4 As the nonwoven fabric of Comparative Example-4, the nonwoven fabric after needle punching of Example-6 was used.

Comparative Example-5 As Comparative Example-5, a commercially available tufted carpet was used.

Table 3 shows the physical property evaluations of Example-6, Comparative Example-4 and Comparative Example-5.

As shown in Table 3, the bulky nonwoven fabric of Example-6 according to the present invention has the same excellent physical properties as those of the Examples shown in Tables 1 and 2, and particularly when the thickness is close to 5 mm. Despite this, the nonwoven fabric has a light weight of 480 g / m ² and is excellent in cushioning properties and abrasion resistance. The nonwoven fabric of Comparative Example-4 is inferior to that of Example-6 in abrasion resistance, cushioning property and bulkiness.

On the other hand, tufted carpet has a large thickness,
Since the weight is heavy, the bulkiness is low. In addition, the dimensional stability is good, but the elongation is small and it is difficult to extend, and the texture becomes hard. Further, it has a property that the compression ratio shows a small value and is difficult to be compressed with a small load.

Manufacturing Conditions of Example-7 Needle punched woven fabric composed of acrylic short fibers as the surface nonwoven fabric (fineness 2 ^d × 38 mm 50%, fineness 8 ^d × 51 mm 5
0%, basis weight 150 g / m ² . Using a single yarn shrinkage ratio of 6%), a spunbonded nonwoven fabric composed of the above-mentioned raw PE filaments as a bottom nonwoven fabric (fineness 16 ^d , basis weight 100 g / m ² , single yarn shrinkage ratio 48)
%) And laminating these two non-woven fabrics, Example-6
Under the same conditions as above, needle punching and heat shrinkage and setting using a tenter are performed to obtain the bulky nonwoven fabric of Example-7.

Comparative Example-6 As the nonwoven fabric of Comparative Example-6, the nonwoven fabric after needle punching of Example-7 was used.

Table 4 shows the physical property evaluations of Example-7 and Comparative Example-6.

As shown in Table 4, the bulky nonwoven fabric according to the present invention of Example-7 exhibits excellent physical properties as in the respective examples shown in Tables 1 to 3 above. On the other hand, the nonwoven fabric of Comparative Example-6 is inferior to Example-7 in each physical property.

<Effects of the Invention> Since the bulky nonwoven fabric according to the present invention is configured as described above, it has a three-dimensional effect and is bulky and soft, and the fibers in a loop state do not come off, and the durability is high during use. Excellent bulky non-woven fabric. Further, the bulky nonwoven fabric according to the present invention has a feature that it can be formed into an arbitrary shape because it has thermoformability.

Further, the bulky nonwoven fabric manufacturing method according to the present invention can be carried out by using various conventionally known fiber processing equipment as described above, and can be mass-produced. Can be produced.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of the bulky nonwoven fabric according to the present invention, and FIG. 2 is a vertical cross-sectional view showing the entangled state of the fibers in the surface nonwoven fabric of the nonwoven fabric of FIG. 1 with the bottom nonwoven fabric. FIG. 3 is a perspective view showing another embodiment of the bulky nonwoven fabric according to the present invention, and FIG. 4 is a longitudinal sectional view showing the entangled state of the fibers in the surface nonwoven fabric of the nonwoven fabric of FIG. 3 with the bottom nonwoven fabric. Is. 1, 2 ... Bulky nonwoven fabric, 10 ... Surface nonwoven fabric, 11 ...
Non-entangled portion, 12 ... Entangled portion, 20 ... Bottom nonwoven fabric, 21 ... Long fibers in bottom nonwoven fabric, 30 ... Recessed portion.

Claims (6)

[Claims] 1. A bulky nonwoven fabric having a two-layer structure comprising a surface nonwoven fabric and a bottom nonwoven fabric, wherein the fibers forming the surface nonwoven fabric are partially physically entangled with the bottom nonwoven fabric and the entanglement. Consisting of non-entangled parts that form a loop projecting upward in an arc shape with the part, whereby the surface of the bulky nonwoven fabric is provided with a large number of loops composed of a plurality of fibers, The fibers forming the bottom nonwoven fabric have a circular cross section with a radius R, and the average refractive index at the center thereof is n.ltoreq. (0) and the average refractive index at a distance of 0.8R from the center is n.ltoreq. (0.8). Then, a bulky non-woven fabric characterized by being polyethylene terephthalate continuous fibers satisfying 1.60 ≦ n / (0) ≦ 1.67 and {n / (0.8) −n / (0)} ≧ 5 × 10 ⁻³ . 2. A method for producing a bulky non-woven fabric having a plurality of loop fibers on the surface by using two kinds of non-woven fabrics having fibers having different physical properties, the production method comprising the following steps. A method for producing a bulky non-woven fabric characterized by: (a) a step of producing a web or dry non-woven fabric composed of arbitrary fibers for a surface non-woven fabric; (b) a breaking elongation of 100% or more, boiling water shrinkage of 5% or more, Assuming that the constituent fiber cross section has a circular cross section with a radius R, the average refractive index at the center of the fiber is n.ltoreq. (0), and the average refractive index at a distance of 0.8R from the center is n.ltoreq. (0.8), n ‖
A step of producing a nonwoven fabric composed of continuous polyethylene terephthalate filaments satisfying (0) ≦ 1.64 and {n / (0.8) -n / (0)} ≧ 5 × 10 ⁻³ as a bottom nonwoven fabric; (c) as the surface nonwoven fabric A step of laminating the produced web or dry nonwoven fabric and the bottom nonwoven fabric; (d) a step of physically entangling the fibers constituting the laminated web or dry nonwoven fabric with the fibers constituting the bottom nonwoven fabric; (e) The laminated non-woven fabric after the physical entanglement is 80 ° C. to 150 ° C.
Shrink finishing step comprising the step of shrinking under heating. 3. The method according to claim 2, wherein the physical entanglement step is performed by needle punching over the entire surface of the laminated nonwoven fabric. 4. The method according to claim 2, wherein said physical entanglement step comprises needle punching over the entire surface of the laminated non-woven fabric, and dot-shaped, broken-line shaped or linear-shaped partial thermocompression bonding performed thereafter. The method described. 5. The method according to claim 2, wherein the shrink finishing step includes a step of widening heat setting of 2 to 10% in the vertical and horizontal directions. 6. The shrinking and finishing step is performed at 80 ° C. to 1 ° C.
The method according to claim 2 or 5, which includes a step of embossing from the bottom nonwoven fabric side after the heat shrinking step at 50 ° C or the widening heat setting step after the heat shrinking step.