JP2001279570A - Composite nonwoven fabric and method for producing the same - Google Patents
Composite nonwoven fabric and method for producing the sameInfo
- Publication number
- JP2001279570A JP2001279570A JP2000094183A JP2000094183A JP2001279570A JP 2001279570 A JP2001279570 A JP 2001279570A JP 2000094183 A JP2000094183 A JP 2000094183A JP 2000094183 A JP2000094183 A JP 2000094183A JP 2001279570 A JP2001279570 A JP 2001279570A
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- fiber
- basis weight
- needle
- fiber diameter
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 101
- 239000002131 composite material Substances 0.000 title claims abstract description 23
- 238000004519 manufacturing process Methods 0.000 title claims description 3
- 239000000835 fiber Substances 0.000 claims abstract description 80
- 238000000034 method Methods 0.000 claims abstract description 30
- 229920001410 Microfiber Polymers 0.000 claims abstract description 27
- 239000004744 fabric Substances 0.000 claims abstract description 21
- 239000004750 melt-blown nonwoven Substances 0.000 claims abstract description 21
- 239000012530 fluid Substances 0.000 claims description 5
- 239000003658 microfiber Substances 0.000 abstract description 3
- 238000004080 punching Methods 0.000 abstract description 3
- 206010016322 Feeling abnormal Diseases 0.000 abstract 1
- 230000010354 integration Effects 0.000 abstract 1
- 238000010521 absorption reaction Methods 0.000 description 17
- 238000010030 laminating Methods 0.000 description 12
- 238000012856 packing Methods 0.000 description 11
- -1 polypropylene Polymers 0.000 description 11
- 229920000139 polyethylene terephthalate Polymers 0.000 description 9
- 239000005020 polyethylene terephthalate Substances 0.000 description 9
- 230000000694 effects Effects 0.000 description 7
- 238000003475 lamination Methods 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 239000000155 melt Substances 0.000 description 6
- 238000001914 filtration Methods 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 2
- 230000001580 bacterial effect Effects 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000013016 damping Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 230000000877 morphologic effect Effects 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 239000002759 woven fabric Substances 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000011358 absorbing material Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 230000002040 relaxant effect Effects 0.000 description 1
- 238000001878 scanning electron micrograph Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Landscapes
- Nonwoven Fabrics (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、柔らかな風合いと
緻密な構造とをあわせ持つ不織布に関する。更に詳しく
は、軽量で薄く形態安定性に優れ、かつ吸音および制振
特性に優れた複合不織布に関する。また、濾過精度が高
くかつライフも長いフィルターに好適な複合不織布に関
する。さらに、防護衣やバクテリアバリアなどの特性に
優れた複合不織布に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonwoven fabric having a soft texture and a dense structure. More specifically, it relates to a composite nonwoven fabric which is lightweight, thin and excellent in form stability, and excellent in sound absorption and vibration damping characteristics. Further, the present invention relates to a composite nonwoven fabric suitable for a filter having high filtration accuracy and a long life. Further, the present invention relates to a composite nonwoven fabric having excellent properties such as protective clothing and a bacterial barrier.
【０００２】[0002]
【従来の技術】従来、極細繊維を含む不織布は優れた吸
音特性やフィルター性、遮蔽性などのすぐれた特性があ
り多くの用途に利用されてきたが、強度が弱かったり、
形態安定性が悪いなどの問題があり、その改善のために
別の不織布と積層複合化して用いられてきた。この際に
不織布を積層一体化する方法としては、スプレーや転写
などでバインダーとなる樹脂を付与する方法や熱融着繊
維などを使用する方法がある。しかしながら、これらの
方法では、乾燥あるいは樹脂の融解接着の目的で熱処理
を行うことが必要であり、環境汚染の問題や省エネルギ
ーの観点からあまり好ましいことではない。また、バイ
ンダー樹脂が不織布間の界面で皮膜を形成し、通気性や
通液性が低下するなどの問題もあった。一方、極細繊維
不織布と長繊維不織布を積層一体化する方法として、ス
パンボンド不織布の間にメルトブローン不織布を積層し
て熱エンボス法で接合する方法が知られている。しかし
ながら、これらの長繊維不織布どうしを接合一体化した
不織布は、ボリューム感に欠け、硬い風合いとなり用途
が制限されてしまうという問題点があった。2. Description of the Related Art Conventionally, nonwoven fabrics containing ultrafine fibers have been used in many applications because of their excellent properties such as excellent sound absorbing properties, filtering properties, and shielding properties.
There are problems such as poor morphological stability, and for improvement, they have been used by laminating and compounding with another nonwoven fabric. At this time, as a method of laminating and integrating the nonwoven fabric, there are a method of applying a resin serving as a binder by spraying or transfer, and a method of using a heat fusion fiber. However, in these methods, it is necessary to perform heat treatment for the purpose of drying or melting and bonding the resin, which is not so preferable from the viewpoint of environmental pollution and energy saving. In addition, there is a problem that the binder resin forms a film at the interface between the nonwoven fabrics, and the air permeability and liquid permeability are reduced. On the other hand, as a method of laminating and integrating a microfiber nonwoven fabric and a long-fiber nonwoven fabric, a method of laminating a meltblown nonwoven fabric between spunbonded nonwoven fabrics and joining them by a hot embossing method is known. However, the nonwoven fabric obtained by joining and integrating these long-fiber nonwoven fabrics has a problem that it lacks voluminous feel, has a hard texture, and is restricted in use.
【０００３】[0003]
【発明が解決しようとする課題】本発明は、柔らかな風
合いで、かつ緻密な構造を持つ複合不織布を安価に提供
することを目的とする。SUMMARY OF THE INVENTION An object of the present invention is to provide a composite nonwoven fabric having a soft texture and a dense structure at a low cost.
【０００４】[0004]
【課題を解決するための手段】本発明は、かかる問題を
解決するために以下の手段をとる。第一の発明は、繊維
径が６ミクロン以下の極細繊維を含有する目付が３０〜
２００ｇ／ｍ2のメルトブローン不織布と、繊維径が７
〜４０ミクロンで目付が５０〜２０００ｇ／ｍ2の短繊
維不織布とがこれらの繊維の交絡により一体化されてい
ることを特徴とする複合不織布である。The present invention employs the following means to solve such a problem. The first invention has a weight per unit area of 30 to 50 μm or less containing ultrafine fibers having a fiber diameter of 6 μm or less.
200 g / m 2 melt blown nonwoven fabric and fiber diameter 7
A composite nonwoven fabric characterized by being integrated with a short-fiber nonwoven fabric having a weight of 50 to 2000 g / m 2 and a fiber weight of ４０40 μm.
【０００５】第２の発明は、繊維径が６ミクロン以下の
極細繊維を含有する目付が３０〜２００ｇ／ｍ2のメル
トブローン不織布と、繊維径が７〜４０ミクロンで目付
が５０〜２０００ｇ／ｍ2の短繊維不織布とを流体交絡
法またはニードルパンチ法のいずれかにより一体化する
事を特徴とする複合不織布の製造方法である。[0005] The second invention is a melt blown nonwoven fabric having a basis weight 30 to 200 g / m 2 of fiber diameter containing the following ultrafine fibers 6 microns, the fiber diameter is basis weight in 7-40 micron 50 to 2000 g / m 2 Characterized in that the nonwoven fabric is integrated with the short fiber nonwoven fabric by either a fluid entanglement method or a needle punch method.
【０００６】[0006]
【発明の実施の形態】以下に本発明を詳細に説明する。
本発明における複合不織布は、少なくとも２種以上の不
織布が接合一体化されていることが必要である。通気性
などをコントロールするために極細繊維を含む不織布層
にフィルムなどを積層する事も望ましい形態のひとつで
ある。また、織布や編物と複合化するのも用途により好
ましい。さらに、該複合不織布の外側に色や模様のつい
た意匠性のある表層不織布を貼り付けても良く、車両内
装材や建築用途の防音材として好適に用いることが可能
である。DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.
The composite nonwoven fabric in the present invention requires that at least two or more nonwoven fabrics are joined and integrated. Laminating a film or the like on a nonwoven fabric layer containing microfibers in order to control the air permeability and the like is also one of the desirable modes. In addition, it is preferable to form a composite with a woven fabric or a knitted fabric depending on the use. Further, a surface non-woven fabric having a design and a color or a pattern may be attached to the outside of the composite non-woven fabric, so that the composite non-woven fabric can be suitably used as a vehicle interior material or a soundproofing material for architectural use.
【０００７】本発明における極細繊維メルトブローン不
織布は、繊維径が６ミクロン以下の極細繊維を重量で１
０％以上含有されていることが好ましい。不織布全体が
極細繊維のみで構成されていてもよいが、含有率が低す
ぎると極細繊維特性による効果が得られにくい。極細繊
維の繊維径は５ミクロン以下がより好ましく、特に好ま
しくは、０．５〜４ミクロンであり、最も好ましくは
１．５〜３ミクロン前後である。メルトブロー法により
得られる不織布は、繊維がランダムに配列することが可
能でフィルター性能や吸音性能を高くすることができる
上に、生産コストが安いため好ましい。[0007] The ultrafine fiber melt blown nonwoven fabric according to the present invention is composed of ultrafine fibers having a fiber diameter of 6 microns or less by weight.
Preferably, it is contained at 0% or more. The entire nonwoven fabric may be composed of only ultrafine fibers, but if the content is too low, it is difficult to obtain the effect of the characteristics of ultrafine fibers. The fiber diameter of the ultrafine fibers is more preferably 5 microns or less, particularly preferably 0.5 to 4 microns, and most preferably about 1.5 to 3 microns. The nonwoven fabric obtained by the melt blow method is preferable because the fibers can be randomly arranged, the filter performance and the sound absorption performance can be improved, and the production cost is low.
【０００８】メルトブローン不織布は強度が弱いので、
スパンボンド不織布など補強用不織布と接合した不織布
を用いたり、積層工程で同時に３層以上の不織布を積層
するのも好ましい。この際、耐摩耗性にすぐれたスパン
ボンド不織布が使用時に表層側にくるように設置するこ
とが好ましい。メルトブローン不織布とスパンボンド不
織布のエンボス加工積層不織布はＳ／Ｍ／ＳやＳ／Ｍな
どの名称で呼ばれ市販されておりこれらを用いるのも好
ましい（Ｓはスパンボンド不織布を、Ｍはメルトブロー
ン不織布を表す）。[0008] Since the melt blown nonwoven fabric has low strength,
It is also preferable to use a nonwoven fabric bonded to a reinforcing nonwoven fabric, such as a spunbonded nonwoven fabric, or to laminate three or more nonwoven fabrics simultaneously in the laminating step. At this time, it is preferable that the spunbonded nonwoven fabric having excellent abrasion resistance is placed on the surface layer side when used. Embossed laminated nonwoven fabric of meltblown nonwoven fabric and spunbonded nonwoven fabric is called S / M / S or S / M and is commercially available. It is also preferable to use these (S is spunbonded nonwoven fabric, M is meltblown nonwoven fabric). Represent).
【０００９】また、分割繊維あるいは海島型繊維のメル
トブローン極細繊維を用いるのも好ましい形態の一つで
ある。分割繊維は予め分割しておいても良いし、積層加
工の際に分割を同時に行っても良い。It is also a preferable embodiment to use a melt-blown ultrafine fiber of split fiber or sea-island type fiber. The split fibers may be split in advance, or split at the time of lamination.
【００１０】本発明におけるメルトブローン極細繊維不
織布は、目付が３０〜２００ｇ／ｍ 2不織布であること
が好ましい。目付が、３０ｇ／ｍ2より小さくなると、
極細繊維の持つ遮蔽性、フィルター性能、柔らかさ、吸
音性などの効果があまり期待できず好ましくない。一
方、目付が２００ｇ／ｍ2を超えると、短繊維不織布と
の複合化する際に皺が入ったり、接合力が弱いという問
題が生じる場合がありあまり好ましくない。また、目付
をあまり大きくしすぎても目的とする遮蔽性、フィルタ
ー性能、柔らかさ、吸音性などの改善効果があまり変わ
らず、コスト削減や軽量化などの観点からあまり好まし
くない。In the present invention, the melt blown ultrafine fiber
The woven fabric has a basis weight of 30 to 200 g / m. TwoBe non-woven
Is preferred. The basis weight is 30 g / mTwoWhen it gets smaller,
The shielding properties, filter performance, softness,
It is not preferable because effects such as sound quality cannot be expected much. one
One, the basis weight is 200 g / mTwoOver, short fiber nonwoven fabric and
Wrinkles and weak bonding when combining
This is not preferred because it may cause problems. Also, the basis weight
Shielding properties and filters even if the size is too large
ー Improved performance, softness, sound absorption, etc.
Not preferred from the viewpoint of cost reduction and weight reduction.
I don't.
【００１１】メルトブローン極細繊維不織布を構成する
素材としては、特に限定はされないが、ポリエステルあ
るいはポリオレフィンがリサイクル性などの観点から特
に好ましい。好ましくは、メルトブローン極細繊維不織
布に積層される短繊維不織布と同じ素材であることがリ
サイクルしやすく特に好ましい。一方、複数の素材より
なる繊維が混合されていても実用上は問題はない。The material constituting the melt blown ultrafine fiber nonwoven fabric is not particularly limited, but polyester or polyolefin is particularly preferred from the viewpoint of recyclability. Preferably, the same material as the short-fiber nonwoven fabric laminated on the meltblown ultrafine-fiber nonwoven fabric is particularly preferable because it is easy to recycle. On the other hand, there is no practical problem even if fibers made of a plurality of materials are mixed.
【００１２】次に、メルトブローン極細繊維不織布と積
層される短繊維不織布は、繊維径が７〜４０ミクロンで
あることが好ましく、特に好ましくは７〜２０ミクロン
である。繊維径が７ミクロンより細いと、カード機から
の紡出性など、生産性の点であまり好ましくない。ま
た、繊維径が７ミクロンより大幅に小さいと、本発明に
よる積層効果が小さくなる。また、不織布が毛羽立ちや
すいなど別の問題を生じる場合がある。繊維径が４０ミ
クロンより太いと、吸音性能やフィルター性能などの目
的とする特性に対する寄与が小さくなりあまり好ましく
ない。この理由は明らかではないが、メルトブローン極
細繊維不織布との特性差が大きすぎるためではないかと
推定できる。Next, the short fiber nonwoven fabric laminated with the melt blown ultrafine fiber nonwoven fabric preferably has a fiber diameter of 7 to 40 microns, particularly preferably 7 to 20 microns. If the fiber diameter is smaller than 7 microns, it is not preferable in terms of productivity such as spinning property from a card machine. If the fiber diameter is much smaller than 7 microns, the laminating effect according to the present invention will be reduced. Another problem may occur in that the nonwoven fabric is easily fluffed. If the fiber diameter is larger than 40 microns, the contribution to the desired properties such as sound absorption performance and filter performance becomes small, which is not preferable. The reason for this is not clear, but it can be assumed that the difference in properties from the melt blown ultrafine fiber nonwoven fabric is too large.
【００１３】本発明において、短繊維の不織布を極細繊
維を含む不織布と積層することにより、メルトブローン
極細繊維不織布が形態安定性が低く（へたりやすかった
り、毛羽立ちやすい）、嵩高性の維持に問題を生じやす
いという欠点を改善したり、高いクッション性を得るな
どの効果が発揮される。また、フィルターとして用いる
際に、濾過ライフやダストあるいは粉塵などの保持量が
長くなるなどの効果を得ることができる。In the present invention, by laminating a nonwoven fabric of short fibers with a nonwoven fabric containing ultrafine fibers, the meltblown ultrafine fiber nonwoven fabric has a low form stability (easy to fluff and easy to fluff) and has a problem in maintaining bulkiness. Effects such as improving the disadvantage of being easily generated and obtaining high cushioning properties are exhibited. Further, when used as a filter, it is possible to obtain effects such as a longer filtration life and a longer retention amount of dust or dust.
【００１４】該短繊維不織布の目付は、５０〜２０００
ｇ／ｍ2の短繊維不織布である。目付が５０ｇ／ｍ2より
小さいと積層効果が小さく不織布の嵩高性や柔らかい風
合いの点であまり好ましくない。一方、２０００ｇ／ｍ
2より大きい目付であると厚みが大きくなりすぎてスペ
ースをとるため用途が限定されてしまうため好ましくな
い。The basis weight of the short fiber non-woven fabric is 50-2000.
g / m 2 short fiber nonwoven fabric. If the basis weight is less than 50 g / m 2 , the laminating effect is small and the nonwoven fabric is not preferred in terms of bulkiness and soft texture. On the other hand, 2000 g / m
A basis weight larger than 2 is not preferable because the thickness becomes too large to take up space and the application is limited.
【００１５】短繊維の長さは３８〜１５０ｍｍが好まし
く、特に好ましくは５０〜１００ｍｍである。複合不織
布を吸音材として用いる場合、繊維長が長いほど優れた
吸音率を示すが、繊維長が長すぎるとカードからの紡出
性が悪くなり好ましくない。短繊維は単一成分でも良い
が、２種類以上の混合物や複数成分の複合繊維でも良
い。不織布の堅さを調整するために重量分率で３０％程
度以下であればさらに太い繊維を混合しても特性はあま
り変化しない。太い繊維が多すぎると不織布風合いが硬
くなりすぎるなどの問題を生じやすくあまり好ましくな
い。融点の異なる熱融着性繊維を用いることも寸法安定
性を改善する観点から好ましい。The length of the short fibers is preferably from 38 to 150 mm, particularly preferably from 50 to 100 mm. When a composite nonwoven fabric is used as a sound absorbing material, the longer the fiber length, the better the sound absorption coefficient is. However, if the fiber length is too long, the spinning property from the card deteriorates, which is not preferable. The short fiber may be a single component, or may be a mixture of two or more types or a multicomponent fiber. If the weight fraction is about 30% or less in order to adjust the hardness of the nonwoven fabric, the characteristics will not change much even if thicker fibers are mixed. If there are too many thick fibers, problems such as the texture of the nonwoven fabric becoming too hard tend to occur, which is not so preferable. It is also preferable to use heat fusible fibers having different melting points from the viewpoint of improving dimensional stability.
【００１６】短繊維不織布の重量ベースの充填密度は、
嵩高性の観点から０．００５〜０．３ｇ／ｃｍ3である
ことが好ましい。充填密度が小さすぎると形態安定性が
悪くなりあまり好ましくない。充填密度が０．３ｇ／ｃ
ｍ3より大きいと嵩高性が悪く本発明の目的を満足する
ことが難しくなる。The packing density on a weight basis of the short fiber nonwoven fabric is as follows:
It is preferably from 0.005 to 0.3 g / cm 3 from the viewpoint of bulkiness. If the packing density is too low, the morphological stability deteriorates, which is not preferred. 0.3g / c packing density
If it is larger than m 3 , the bulkiness is poor and it is difficult to satisfy the object of the present invention.
【００１７】本発明における不織布の積層一体化方法
は、流体交絡法あるいはニードルパンチ法のいずれかに
より一体化する。ニードルパンチ法は不織布加工方法と
して一般的に実施されている方法が採用でき、例えば、
日本繊維機械学会不織布研究会編集の「不織布の基礎と
応用」などで解説されている方法である。前記のメルト
ブローン不織布と短繊維不織布とをニードルパンチ法を
用いて複合化すると、メルトブローン極細繊維不織布に
穴が開いて、吸音性能やフィルター性能などが低下して
しまうことが一般的には、予想されるが、意外なことに
本発明においては、そのような欠点の発現がない。In the method of laminating and integrating the nonwoven fabric according to the present invention, the nonwoven fabric is integrated by either a fluid entanglement method or a needle punch method. Needle punch method can be adopted a method that is generally implemented as a nonwoven fabric processing method, for example,
This is a method described in "Foundations and applications of nonwoven fabrics" edited by the Japan Society of Textile Machinery Nonwovens Study Group. When the meltblown nonwoven fabric and the short-fiber nonwoven fabric are combined using the needle punch method, it is generally expected that holes will be formed in the meltblown ultrafine fiber nonwoven fabric, and that sound absorption performance and filter performance will be reduced. However, surprisingly, the present invention does not exhibit such disadvantages.
【００１８】ニードルパンチ加工を行う際には、３８番
手より細いニードル（針）を用いることが好ましく、特
に好ましくは４０〜４２番手である。ニードルは、短繊
維不織布側から入り、メルトブローン極細繊維を含有す
る不織布の外側に、短繊維のループを生じさせることが
好ましい。メルトブローン極細繊維不織布は、繊維が他
の物に引っかかったり、それにより切断されたりして毛
羽立ちやすいが、短繊維のループは、メルトブローン不
織布の表面毛羽立ちを防止したり、クッション層になっ
て、メルトブローン不織布層にかかる外力を緩和するこ
とで破壊の防止に役立つ効果がある。When performing the needle punching, it is preferable to use a needle (needle) finer than 38th, and particularly preferably 40 to 42th. Preferably, the needle enters from the short-fiber nonwoven fabric side and forms a short-fiber loop outside the nonwoven fabric containing the meltblown ultrafine fibers. The meltblown nonwoven fabric is easy to fuzz because the fiber is caught by other objects or cut by it, but the short fiber loop prevents the surface from fluffing of the meltblown nonwoven fabric, or becomes a cushion layer to form a meltblown nonwoven fabric. Relaxing the external force applied to the layer is effective in preventing breakage.
【００１９】また、別の不織布やフィルムなどと積層す
る際に、短繊維のループと積層相手の第３の素材を接着
することで、曲げや引っ張りなどの外力がかかったとき
にメルトブローン不織布が破壊されるのを防止すること
が可能となる。適切なループの大きさを形成するため
に、ニードルパンチの針深度は１５ｍｍ以下であること
が好ましい。針深度が１５ｍｍを超えると、メルトブロ
ーン極細繊維不織布を針および短繊維が貫通するときの
衝撃で該不織布が破れたり、貫通した後の針穴が大きく
なりすぎることが多くなりあまり好ましくない。針深度
は、ニードルのバーブの位置にもよるが５ｍｍ以上であ
ることが、不織布の交絡を増やして剥離を防止する上で
好ましい。Further, when laminating with another non-woven fabric or film, the loop of short fibers and the third material to be laminated are adhered to each other, so that the melt blown non-woven fabric is broken when an external force such as bending or pulling is applied. Can be prevented from being performed. In order to form an appropriate loop size, the needle depth of the needle punch is preferably 15 mm or less. If the needle depth exceeds 15 mm, the nonwoven fabric breaks due to the impact when the needles and short fibers penetrate the meltblown ultrafine fiber nonwoven fabric, and the needle hole after the penetration becomes too large, which is not preferable. The needle depth depends on the barb position of the needle, but is preferably 5 mm or more in order to increase the entanglement of the nonwoven fabric and prevent peeling.
【００２０】刺孔密度は３０〜２００本／ｃｍ2である
ことが好ましい。刺孔密度が３０本／ｃｍ2より小さい
と不織布の剥離の問題が生じやすく、２５０本／ｃｍ2
より大きいと刺孔による開口総面積が大きすぎたり、メ
ルトブローン極細繊維不織布の破れや破壊を生じやすく
あまり好ましくない。The puncture density is preferably 30 to 200 holes / cm 2 . If the puncture density is less than 30 holes / cm 2 , the problem of peeling of the nonwoven fabric is likely to occur, and 250 holes / cm 2
If it is larger, the total opening area due to the piercing hole is too large, or the melt-blown ultrafine fiber nonwoven fabric is easily broken or broken, which is not preferable.
【００２１】次に、流体交絡法は、流体を作用させるこ
とで繊維の交絡を生じさせる方法であり、水流交絡法が
一般的である。水流交絡法では、一般的に、水流の跡が
筋状に残りやすいことが知られており、このために嵩高
の不織布とメルトブローン極細繊維不織布との積層手段
として水流交絡法を用いる事は一般的ではなかったが、
本発明者は、短繊維不織布の目付が３００ｇ／ｍ2以下
と小さい際には、特に短繊維不織布の柔らかい風合いを
あまり損なうことなく積層加工が可能であることを見出
したのである。Next, the fluid entanglement method is a method in which fibers are entangled by applying a fluid, and the water entanglement method is generally used. In the hydroentanglement method, it is generally known that traces of the water flow are likely to remain in a streak shape. For this reason, it is common to use the hydroentanglement method as a laminating means of a bulky nonwoven fabric and a meltblown ultrafine fiber nonwoven fabric. Was not
The present inventor has found that when the basis weight of the short-fiber nonwoven fabric is as small as 300 g / m 2 or less, lamination can be carried out without particularly impairing the soft feel of the short-fiber nonwoven fabric.
【００２２】[0022]
【実施例】以下に本発明を実施例をあげて説明する。な
お、評価方法は、以下の方法によった。 （平均繊維径）：走査型電子顕微鏡写真を適当な倍率で
とり、繊維側面を２０本以上測定して、その平均値から
求めた。極細繊維不織布がメルトブロー法の場合は、繊
維径のバラツキが大きいため１００本以上を測定して平
均値を採用した。The present invention will be described below with reference to examples. In addition, the evaluation method was based on the following method. (Average fiber diameter): A scanning electron micrograph was taken at an appropriate magnification, 20 or more fiber sides were measured, and the average value was obtained. In the case where the ultrafine fiber nonwoven fabric is a melt blow method, the dispersion of the fiber diameter is large, so that 100 or more fibers were measured and the average value was adopted.
【００２３】（目付および充填密度）：不織布を２０ｃ
ｍ角に切り出してその重量を測定した値を１ｍ2あたり
に換算して目付とした。充填密度は、不織布の目付を２
０ｇ／ｃｍ2の荷重下での厚みで割った値を求めて、ｇ
／ｃｍ3に単位換算して求めた。(Fabric weight and packing density): Non-woven fabric 20c
It was cut out into m-squares and the measured weight was converted to about 1 m 2 to obtain the basis weight. Packing density is 2
A value obtained by dividing the thickness under a load of 0 g / cm 2 by g
/ Cm 3 as a unit.
【００２４】（剥離）：複合した不織布を手で９０度前
後折り曲げる動作を２０回繰り返して、剥離が生じるか
どうかを目視で評価した。(Peeling): The operation of bending the composite nonwoven fabric back and forth by 90 degrees by hand was repeated 20 times, and it was visually evaluated whether peeling occurred.
【００２５】（吸音率）：ＪＩＳ Ａ−１４０５に従っ
て、垂直入射法吸音率を求めた。代表値として１０００
Ｈｚと２０００Ｈｚの値の平均値を用いた。(Sound absorption coefficient): The sound absorption coefficient by the normal incidence method was determined in accordance with JIS A-1405. 1000 as representative value
The average value of Hz and 2000 Hz was used.
【００２６】実施例１ 平均繊維径３ミクロン、目付１００ｇ／ｍ2のポリプロ
ピレン製メルトブローン不織布の上に、平均繊維径１４
ミクロン、繊維長５１ｍｍ、捲縮数12個／インチの短繊
維よりなる目付２５０ｇ／ｍ2、充填密度０．０６ｇ／
ｃｍ3のポリエチレンテレフタレート製ニードルパンチ
不織布を重ねて、４０番手のニードルを用いて、刺孔密
度５０本／ｃｍ2、針深度１０ｍｍでニードルパンチ積
層加工を実施した。この複合不織布を２０回程度折り曲
げても剥離の問題は生じず、吸音率も６８％と高く良好
であった。Example 1 An average fiber diameter of 14 μm was formed on a polypropylene melt-blown nonwoven fabric having an average fiber diameter of 3 μm and a basis weight of 100 g / m 2.
Micron, fiber length 51 mm, crimp count: 12 g / m 2 , short fiber having a basis weight of 250 g / m 2 , packing density: 0.06 g /
A needle-punched nonwoven fabric made of polyethylene terephthalate of cm 3 was overlaid, and a needle-punch lamination process was performed using a 40th needle at a puncture density of 50 needles / cm 2 and a needle depth of 10 mm. Even if this composite nonwoven fabric was bent about 20 times, the problem of peeling did not occur, and the sound absorption was as high as 68%, which was good.
【００２７】実施例２ 平均繊維径１４ミクロン、目付２０ｇ／ｍ2のポリエチ
レンテレフタレート製スパンボンドン不織布の上に平均
繊維径３ミクロン、目付１００ｇ／ｍ2のポリエチレン
テレフタレート製メルトブローン不織布を重ね、さらに
その上に平均繊維径１４ミクロン、繊維長５１ｍｍ、捲
縮数12個／インチの短繊維よりなる目付２５０ｇ／
ｍ2、充填密度０．０６ｇ／ｃｍ3のポリエチレンテレフ
タレート製ニードルパンチ不織布を重ねて、４０番手の
ニードルを用いて、刺孔密度５０本／ｃｍ2、針深度１
０ｍｍでニードルパンチ積層加工を実施した。この複合
不織布を２０回程度折り曲げても剥離の問題は生じず、
吸音率も７１％と高く良好であった。Example 2 A polyethylene terephthalate melt-blown nonwoven fabric having an average fiber diameter of 3 μm and a basis weight of 100 g / m 2 was overlaid on a polyethylene terephthalate spunbonded nonwoven fabric having an average fiber diameter of 14 μm and a basis weight of 20 g / m 2. An average fiber diameter of 14 micron, a fiber length of 51 mm, and a crimping number of 12 pieces / inch.
A needle-punched nonwoven fabric made of polyethylene terephthalate having an m 2 of 0.06 g / cm 3 and a packing density of 0.06 g / cm 3 is superimposed, and a puncture density of 50 needles / cm 2 and a needle depth of 1 are obtained using a 40th needle.
Needle punch lamination processing was performed at 0 mm. Even if this composite nonwoven fabric is bent about 20 times, the problem of peeling does not occur,
The sound absorption coefficient was as high as 71%, which was good.
【００２８】実施例３ 平均繊維径３ミクロン、目付５０ｇ／ｍ2のポリエチレ
ンテレフタレート製メルトブローン不織布の下に、平均
繊維径１４ミクロン、繊維長５１ｍｍ、捲縮数12個／イ
ンチの短繊維よりなる目付２５０ｇ／ｍ2、充填密度
０．０６ｇ／ｃｍ３のポリエチレンテレフタレート製ニ
ードルパンチ不織布をセットして、直径０．１ｍｍ、孔
ピッチ１ｍｍ、孔列数２列のプレートを用いて水圧３０
ｋｇｆ／ｃｍ2で水流交絡積層加工を２度実施した。こ
の時のノズルと不織布の間の距離はほぼ１インチあっ
た。この複合不織布を２０回程度折り曲げても剥離の問
題は生じず、吸音率も５９％と高く良好であった。Example 3 Under a melt-blown nonwoven fabric made of polyethylene terephthalate having an average fiber diameter of 3 μm and a basis weight of 50 g / m 2 , a basis weight comprising short fibers having an average fiber diameter of 14 μm, a fiber length of 51 mm and a number of crimps of 12 / inch. A polyethylene terephthalate needle-punched nonwoven fabric having a packing density of 250 g / m 2 and a packing density of 0.06 g / cm 3 was set, and a water pressure of 30 mm was set using a plate having a diameter of 0.1 mm, a hole pitch of 1 mm, and two holes.
The hydroentanglement lamination processing was performed twice at kgf / cm 2 . At this time, the distance between the nozzle and the nonwoven fabric was approximately 1 inch. Even if this composite nonwoven fabric was bent about 20 times, no problem of peeling occurred, and the sound absorption was as high as 59%, which was good.
【００２９】比較例１ 実施例１で用いた２種の不織布を、アクリル系樹脂バイ
ンダーを１５ｇ／ｍ2塗布することで不織布を複合化し
た。複合不織布を折り曲げても初期の剥離の問題は生じ
なかったが、繰り返すと部分的な剥離を生じて問題であ
った。メルトブローン不織布構成繊維の接着が弱く、内
部で破壊を生じたと考えらる。吸音率は７０％と高く実
施例１と同等で良好であった。吸音率は実施例１より若
干高いが、樹脂の付着分の効果も考慮すると、ニードル
パンチによる刺孔の跡による差はなく、吸音率の測定誤
差程度と考えられる。Comparative Example 1 The two types of nonwoven fabrics used in Example 1 were coated with an acrylic resin binder at 15 g / m 2 to form a composite of the nonwoven fabrics. Even if the composite nonwoven fabric was bent, the problem of initial peeling did not occur, but repeated peeling caused partial peeling. It is considered that the adhesion of the constituent fibers of the meltblown nonwoven fabric was weak, and the inside was broken. The sound absorption coefficient was as high as 70%, which was as good as that of Example 1. Although the sound absorption coefficient is slightly higher than that of Example 1, there is no difference due to the trace of the puncture hole due to the needle punch when the effect of the resin adhesion is considered, and it is considered that the sound absorption coefficient is about a measurement error.
【００３０】比較例２ 平均繊維径３ミクロン、目付１５ｇ／ｍ2のポリプロピ
レン製メルトブローン不織布の上に、平均繊維径１４ミ
クロン、繊維長５１ｍｍ、捲縮数12個／インチの短繊維
よりなる目付２５０ｇ／ｍ2、充填密度０．０６ｇ／ｃ
ｍ3のポリエチレンテレフタレート製ニードルパンチ不
織布を重ねて、３２番手のニードルを用いて、刺孔密度
５０本／ｃｍ2、針深度１８ｍｍでニードルパンチ積層
加工を実施した。積層不織布１ｍ2あたりに５〜２０程
度のメルトブロー不織布が針穴近傍で破れが発生してお
り問題であった。複合不織布を折り曲げても剥離の問題
は生じなかったが、破れの箇所が増加して問題であっ
た。破れのない箇所の吸音率を測定したが、２８％と低
く問題であった。COMPARATIVE EXAMPLE 2 A melt-blown nonwoven fabric made of polypropylene having an average fiber diameter of 3 μm and a basis weight of 15 g / m 2 , and a basis weight of 250 g of short fibers having an average fiber diameter of 14 μm, a fiber length of 51 mm and a number of crimps of 12 / inch. / M 2 , packing density 0.06 g / c
A needle-punched nonwoven fabric made of polyethylene terephthalate of m 3 was stacked, and needle-punch lamination was performed using a 32nd needle at a puncture density of 50 needles / cm 2 and a needle depth of 18 mm. Meltblown nonwoven of about 5 to 20 per layered nonwoven fabric 1 m 2 was broken has occurred a problem with the needle hole near. Although the problem of peeling did not occur even if the composite nonwoven fabric was bent, the number of torn spots increased, which was a problem. The sound absorption coefficient of a portion where there was no breakage was measured.
【００３１】比較例３ 平均繊維径１４ミクロン、繊維長５１ｍｍ、捲縮数12個
／インチの短繊維よりなる目付５００ｇ／ｍ2のポリエ
チレンテレフタレート製短繊維ウエッブを４０番手のニ
ードルを用いて、表と裏の両方からそれぞれ刺孔密度３
０本／ｃｍ2、針深度１０ｍｍでニードルパンチ加工し
て、充填密度０．０５ｇ／ｃｍ3嵩高不織布を得た。吸
音率を測定したが、２１％と低く問題であった。Comparative Example 3 A short web of polyethylene terephthalate made of polyethylene terephthalate having an average fiber diameter of 14 μm, a fiber length of 51 mm, and a crimp count of 12 / inch and having a basis weight of 500 g / m 2 was prepared using a 40th needle. Puncture density of 3 from both sides
Needle punching was performed at 0 needles / cm 2 and a needle depth of 10 mm to obtain a bulked nonwoven fabric having a packing density of 0.05 g / cm 3 . The sound absorption coefficient was measured and found to be 21%, which was a problem.
【００３２】[0032]
【発明の効果】本発明により、柔らかな風合いで、かつ
緻密な構造を持つ複合不織布を提供することが可能とな
る。特に、軽量で薄い吸音および制振特性にすぐれた不
織布あるいは、濾過精度が高くかつライフも長いフィル
ターに好適な不織布、あるいは防護衣やバクテリアバリ
アなどの特性に優れた不織布として産業上の広い用途で
好適に使用される。According to the present invention, it is possible to provide a composite nonwoven fabric having a soft texture and a dense structure. In particular, it is widely used in a wide range of industrial applications as a lightweight and thin nonwoven fabric with excellent sound absorption and vibration damping properties, a nonwoven fabric suitable for filters with high filtration accuracy and long life, or a nonwoven fabric with excellent properties such as protective clothing and bacterial barrier. It is preferably used.
Claims (2)
する目付が３０〜２００ｇ／ｍ2のメルトブローン不織
布と、繊維径が７〜４０ミクロンで目付が５０〜２００
０ｇ／ｍ2の短繊維不織布とがこれらの繊維の交絡によ
り一体化されていることを特徴とする複合不織布。1. A and meltblown nonwoven fiber diameter containing the following ultrafine fibers 6 microns basis weight 30 to 200 g / m 2, fiber diameter in the 7-40 micron basis weight of 50 to 200
A composite nonwoven fabric characterized by being integrated with a short-fiber nonwoven fabric of 0 g / m 2 by entanglement of these fibers.
する目付が３０〜２００ｇ／ｍ2のメルトブローン不織
布と、繊維径が７〜４０ミクロンで目付が５０〜２００
０ｇ／ｍ2の短繊維不織布とを流体交絡法またはニード
ルパンチ法のいずれかにより一体化する事を特徴とする
複合不織布の製造方法。 2. A melt-blown nonwoven fabric having a basis weight of 30 to 200 g / m 2 containing ultrafine fibers having a fiber diameter of 6 μm or less, and a fiber diameter of 7 to 40 μm and a basis weight of 50 to 200 g / m 2.
A method for producing a composite nonwoven fabric, comprising integrating a short fiber nonwoven fabric of 0 g / m 2 by a fluid entanglement method or a needle punch method.
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|---|---|---|---|
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000094183A JP3705413B2 (en) | 2000-03-30 | 2000-03-30 | Composite nonwoven fabric and method for producing the same |
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| Publication Number | Publication Date |
|---|---|
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ID=18609269
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| JP2004019062A (en) * | 2002-06-18 | 2004-01-22 | Toyobo Co Ltd | Acoustic material |
| JP2004021037A (en) * | 2002-06-18 | 2004-01-22 | Toyobo Co Ltd | Acoustic absorption material and interior material for vehicle |
| JP2005178316A (en) * | 2003-12-24 | 2005-07-07 | Toyota Boshoku Corp | Laminated nonwoven fabric and inner trim material of automobile |
| JP2010526216A (en) * | 2007-05-02 | 2010-07-29 | イー・アイ・デュポン・ドウ・ヌムール・アンド・カンパニー | Needle punched nanoweb structure |
| JP2017080708A (en) * | 2015-10-30 | 2017-05-18 | タイガースポリマー株式会社 | Manufacturing method for unwoven fabric filter medium |
| JP2018518382A (en) * | 2015-03-31 | 2018-07-12 | フロイデンベルグ パフォーマンス マテリアルズ エルピー | Moldable composite mat |
| CN108866830A (en) * | 2018-08-24 | 2018-11-23 | 芜湖跃飞新型吸音材料股份有限公司 | A kind of two-component car bra acoustical cotton and preparation method thereof |
| CN108950862A (en) * | 2018-08-24 | 2018-12-07 | 芜湖跃飞新型吸音材料股份有限公司 | A kind of multicomponent interlayer type automobile acoustical cotton and preparation method thereof |
| WO2020137605A1 (en) * | 2018-12-28 | 2020-07-02 | クラレクラフレックス株式会社 | Fiber structure and application thereof |
| JPWO2021010178A1 (en) * | 2019-07-16 | 2021-01-21 | ||
| JP2022117628A (en) * | 2021-02-01 | 2022-08-12 | 旭化成株式会社 | sound absorbing material |
| WO2023282088A1 (en) * | 2021-07-07 | 2023-01-12 | クラレクラフレックス株式会社 | Fiber structure and use thereof |
| JP2023549091A (en) * | 2020-10-30 | 2023-11-22 | アセンド・パフォーマンス・マテリアルズ・オペレーションズ・リミテッド・ライアビリティ・カンパニー | Polyamide nonwovens in sound-absorbing multilayer composites |
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Cited By (19)
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| JP2004021037A (en) * | 2002-06-18 | 2004-01-22 | Toyobo Co Ltd | Acoustic absorption material and interior material for vehicle |
| JP2004019062A (en) * | 2002-06-18 | 2004-01-22 | Toyobo Co Ltd | Acoustic material |
| JP2005178316A (en) * | 2003-12-24 | 2005-07-07 | Toyota Boshoku Corp | Laminated nonwoven fabric and inner trim material of automobile |
| JP2010526216A (en) * | 2007-05-02 | 2010-07-29 | イー・アイ・デュポン・ドウ・ヌムール・アンド・カンパニー | Needle punched nanoweb structure |
| JP2018518382A (en) * | 2015-03-31 | 2018-07-12 | フロイデンベルグ パフォーマンス マテリアルズ エルピー | Moldable composite mat |
| JP2017080708A (en) * | 2015-10-30 | 2017-05-18 | タイガースポリマー株式会社 | Manufacturing method for unwoven fabric filter medium |
| CN108950862B (en) * | 2018-08-24 | 2021-04-16 | 芜湖跃飞新型吸音材料股份有限公司 | Multi-component sandwich type sound-absorbing cotton for automobile and preparation method thereof |
| CN108866830A (en) * | 2018-08-24 | 2018-11-23 | 芜湖跃飞新型吸音材料股份有限公司 | A kind of two-component car bra acoustical cotton and preparation method thereof |
| CN108950862A (en) * | 2018-08-24 | 2018-12-07 | 芜湖跃飞新型吸音材料股份有限公司 | A kind of multicomponent interlayer type automobile acoustical cotton and preparation method thereof |
| WO2020137605A1 (en) * | 2018-12-28 | 2020-07-02 | クラレクラフレックス株式会社 | Fiber structure and application thereof |
| CN113260750A (en) * | 2018-12-28 | 2021-08-13 | 可乐丽可乐富丽世股份有限公司 | Fiber structure and use thereof |
| JPWO2020137605A1 (en) * | 2018-12-28 | 2021-11-18 | クラレクラフレックス株式会社 | Fiber structure and its uses |
| WO2021010178A1 (en) * | 2019-07-16 | 2021-01-21 | クラレクラフレックス株式会社 | Fiber structure and production method therefor |
| JPWO2021010178A1 (en) * | 2019-07-16 | 2021-01-21 | ||
| CN114126742A (en) * | 2019-07-16 | 2022-03-01 | 可乐丽可乐富丽世股份有限公司 | Fiber structure and method for producing same |
| CN114126742B (en) * | 2019-07-16 | 2024-05-03 | 可乐丽可乐富丽世股份有限公司 | Fiber structure and method for producing same |
| JP2023549091A (en) * | 2020-10-30 | 2023-11-22 | アセンド・パフォーマンス・マテリアルズ・オペレーションズ・リミテッド・ライアビリティ・カンパニー | Polyamide nonwovens in sound-absorbing multilayer composites |
| JP2022117628A (en) * | 2021-02-01 | 2022-08-12 | 旭化成株式会社 | sound absorbing material |
| WO2023282088A1 (en) * | 2021-07-07 | 2023-01-12 | クラレクラフレックス株式会社 | Fiber structure and use thereof |
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