JP2018035468A - Compound type non-woven fabric and manufacturing method thereof - Google Patents

Abstract

Disclosed is a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer, and a nonwoven fabric suitable for a wiper is provided.
A composite nonwoven fabric CWeb in which a pulp fiber layer FP is laminated and integrated on a synthetic fiber layer SW, and uneven portions DE and PR are formed on the surface of the pulp fiber layer FP. A plurality of the concavo-convex portions may be formed in a line shape, or a plurality of the concavo-convex portions may be formed in a vertical and horizontal lattice shape.
[Selection] Figure 1

Description

  The present invention relates to a composite nonwoven fabric composed of pulp fibers and synthetic fibers and a method for producing the same. More specifically, the present invention relates to a non-woven fabric suitable as a so-called wiper used as a towel, towel, towel, waste cloth or the like.

The nonwoven fabric has a cloth-like texture, and also has liquid absorption and wiping properties (sometimes referred to as scraping properties), and can be mass-produced. For this reason, nonwoven fabrics are widely used in various fields.
Generally, a nonwoven fabric is manufactured through the web formation process which forms the web used as a base material (it may be called a fleece), and the fiber bonding process which couple | bonds the fiber which comprises a web mutually. And many proposals are conventionally made about each of a web formation process and a fiber bonding process.

  For example, as disclosed in Patent Document 1, a pulp fiber layer (web) and a synthetic fiber layer (web) are overlapped to form a laminated web, and then a high-pressure water jet (water stream) is blown to hydroentanglement treatment. By combining the fibers, a composite nonwoven fabric can be obtained. As described above, the composite nonwoven fabric formed by the pulp fiber layer and the synthetic fiber layer is advantageous in that the pulp fiber has good absorbability for both aqueous and oily liquids, and the synthetic fiber has excellent strength. An excellent non-woven fabric product that has both can be provided to consumers as a wiper.

Japanese Patent No. 2533260

Desirably, the nonwoven fabric employed as the wiper has improved liquid absorption performance and wiping performance over ordinary nonwoven fabric.
Here, for example, the higher the basis weight, the higher the liquid absorbency can be expected. However, when the basis weight increases, the so-called stiff feeling increases and the adhesion to the object to be wiped is impaired. Therefore, although the nonwoven fabric which can satisfy both liquid absorption property and wiping property is desired, the nonwoven fabric suitable for the wiper which satisfy | fills this request | requirement has not yet been provided.
In addition, it is also conceivable to apply a surface treatment to the web of the manufactured nonwoven fabric (before drying or after drying) to improve the liquid absorption and wiping properties later. In this case, however, an additional device is required, which increases costs due to an increase in manufacturing facilities. Therefore, it is preferable that the manufactured nonwoven fabric itself is in the form of a raw fabric and is in a form having excellent liquid absorption and wiping properties. However, the nonwoven fabric is suitable for a wiper designed from such a viewpoint. Has not existed in the past.

  Therefore, a main object of the present invention is to provide a nonwoven fabric suitable for a wiper, which is a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer. Moreover, it is providing the manufacturing method which can manufacture this nonwoven fabric comparatively easily.

The above object can be achieved by a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer, and a concave and convex portion is formed on the surface of the pulp fiber layer.
A plurality of the concavo-convex portions may be formed in a line shape, or a plurality of the concavo-convex portions may be formed in a vertical and horizontal lattice shape.

  As for the said uneven part, it is desirable for the height difference dimension of the bottom part of a recessed part and the top part of a convex part to be 200-800 micrometers.

  The above object is a method for producing a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer, and is placed on the synthetic fiber layer and the synthetic fiber layer. At least a hydroentanglement step of spraying a water jet toward the preliminary laminate formed by the pulp fibers to perform hydroentanglement and promoting integration of the pulp fiber layer and the synthetic fiber layer, In the water entanglement step, the preliminary laminate is placed and conveyed on a conveyance wire, and the water jet is sprayed toward the pulp fiber layer from a plurality of water jet nozzles arranged in a direction perpendicular to the conveyance direction. Suction with a suction device arranged below the conveying wire, and a position corresponding to the water jet nozzle as a recess, a plurality of streaky irregularities on the surface of the pulp fiber layer It is achieved by the method for producing a composite nonwoven fabric formed.

  The plurality of water jet nozzles preferably have a nozzle diameter of 0.15 to 0.25 mm, and the plurality of water jet nozzles are preferably arranged in a plurality of stages along the transport direction.

  Furthermore, before and after the second hydroentanglement process by the plurality of water jet nozzles, a water jet is directed toward the entire surface of the pulp fiber layer using a water jet nozzle having a diameter smaller than that of the plurality of water jet nozzles. It is more preferable to perform the first hydroentanglement process of spraying.

  The above object is also a method for producing a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer, and the synthetic fiber layer is placed on the synthetic fiber layer. At least a hydroentanglement step of spraying a water jet toward the preliminary laminate formed by the pulp fibers to perform hydroentanglement and promoting integration of the pulp fiber layer and the synthetic fiber layer. In the hydroentanglement step, the preliminary laminated body is placed on a transport wire and transported, and the water jet is sprayed toward the pulp fiber layer from a plurality of water spray nozzles arranged in a direction perpendicular to the transport direction. In addition, suction is performed by a suction device disposed below the transport wire, and a plurality of impermeable portions are disposed in the suction device along a direction perpendicular to the transport direction. Corresponding to the position of the water part, by forming a plurality of recesses in the surface of the pulp fiber layer, also achieved by the method for producing a composite nonwoven fabric forming a plurality of stripe-like concavo-convex portion.

  The above object is also a method for producing a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer, and the synthetic fiber layer is placed on the synthetic fiber layer. At least a hydroentanglement step of spraying a water jet toward the preliminary laminate formed by the pulp fibers to perform hydroentanglement and promoting integration of the pulp fiber layer and the synthetic fiber layer. In the hydroentanglement step, the preliminary laminated body is placed on a transport wire and transported, and the water jet is sprayed toward the pulp fiber layer from a plurality of water spray nozzles arranged in a direction perpendicular to the transport direction. In addition, suction is performed by a suction device disposed below the transport wire, and the transport wire is formed by a plurality of warp yarns and weft yarns, and at least one of the warp yarns and the weft yarns. About, having a form in which a plurality of thick yarns with a diameter larger than other yarns are arranged at intervals, by forming a plurality of recesses on the surface of the pulp fiber layer corresponding to the position of the thick yarn, This can also be achieved by a method for producing a composite nonwoven fabric in which a plurality of streaky uneven portions or a plurality of vertical and horizontal lattice-shaped uneven portions are formed.

  In addition, you may employ | adopt the manufacturing method which manufactures the said composite type nonwoven fabric by combining two or more from the several manufacturing method described above.

Since the nonwoven fabric of this invention has several uneven | corrugated | grooved parts formed in the pulp fiber layer on a synthetic fiber layer, it is excellent in liquid absorption and wiping off, and becomes a nonwoven fabric suitable as a wiper.
A nonwoven fabric having such a morphological characteristic of having a plurality of irregularities in the pulp fiber layer in a raw fabric state is manufactured by the manufacturing method proposed in the present invention with a simple improvement to the manufacturing process. can do.
In addition, arbitrary unevenness | corrugation can be formed in the nonwoven fabric obtained by the conventional general manufacturing process using the embossing processing apparatus provided with the heating and pressurizing means, for example. However, in this case, an embossing device is further required, and there is a concern that the texture and strength of the nonwoven fabric are reduced by the heat treatment. The nonwoven fabric of the present invention is a nonwoven fabric in which such concerns have been eliminated.

It is the figure which showed typically the composite type nonwoven fabric which concerns on this invention. It is the figure which showed the basic composition of the manufacturing apparatus for manufacturing the composite type nonwoven fabric which concerns on this invention. It is the figure shown in order to demonstrate the 1st method for manufacturing a composite type nonwoven fabric. It is the figure shown in order to demonstrate the 2nd method for manufacturing a composite type nonwoven fabric. It is the figure shown in order to demonstrate the 3rd method for manufacturing a composite type nonwoven fabric.

Hereinafter, a composite nonwoven fabric according to an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a schematic view showing a part of a composite nonwoven fabric CWeb. In FIG. 1, a synthetic fiber layer (hereinafter sometimes referred to as a synthetic fiber layer SW) composed of a synthetic fiber web SW located on the lower side, and a pulp fiber layer (hereinafter referred to as a synthetic fiber layer SW) disposed thereon. , And may be described as a pulp fiber layer FP).
The nonwoven fabric CWeb according to the present invention is a composite nonwoven fabric in which the synthetic fiber layer SW and the pulp fiber layer FP are integrated. And in FIG. 1, the form by which the several uneven | corrugated | grooved part is repeatedly formed with the same form on the surface of the pulp fiber layer FP located on the upper side is illustrated.

The concave and convex portion is formed by the concave portion DE and the convex portion PR, but if a concave portion (or convex portion) is repeatedly formed on the surface of the pulp fiber layer FP, a convex portion (or concave portion) is relatively formed therebetween. Will be.
In FIG. 1, the nonwoven fabric CWeb when the uneven | corrugated | grooved parts DE and PR are formed in multiple stripes is illustrated. The manufacturing method of this nonwoven fabric CWeb will be clarified in the following description.
Although not shown in the drawings, a plurality of the concavo-convex portions DE and PR may be formed in a vertical and horizontal lattice shape (mesh shape or mesh shape). The manufacturing method of this nonwoven fabric CWeb will also be clarified in the following description.

As described above, the nonwoven fabric CWeb according to the present invention has pulp fibers arranged on the surface thereof, and the surface has uneven portions, so that the liquid absorption performance is improved by increasing the surface area. Moreover, since the function which hold | maintains the dirt which was scooped in the convex part in a recessed part is also provided, the wiping performance improves.
Therefore, it becomes a nonwoven fabric suitable for a wiper with improved liquid absorption and wiping properties. This non-woven fabric CWeb is obtained by a novel manufacturing method, and has a plurality of uneven portions on the pulp fiber layer on the surface as a morphological characteristic of the web raw fabric. Therefore, the nonwoven fabric is excellent in flexibility, texture and bulkiness.
In addition, from the viewpoint that the nonwoven fabric CWeb ensures liquid absorption performance and wiping performance, the height difference between the bottom of the concave portion DE and the top of the convex portion PR is, for example, 200 to 800 μm with respect to the concave and convex portions DE and PR. It is preferable to do this. Thereby, reliable wiping performance can be expected.
Furthermore, the width of the convex part PR is, for example, 0.5 to 3.0 mm, and the predetermined interval (the width of the concave part DE) is preferably, for example, 0.3 to 1.0 mm.

Hereinafter, the manufacturing method of the said nonwoven fabric CWeb is demonstrated. There are three preferred forms of manufacturing methods. First, after describing the main configuration of the nonwoven fabric CWeb manufacturing apparatus, the characteristic configuration of each manufacturing method will be described individually.
The composite nonwoven fabric production apparatus 1 shown in FIG. 2 includes an airlaid apparatus 2 as a pulp airlaid section, a synthetic fiber web supply apparatus 3 as a synthetic fiber layer supply section, and a suction apparatus 4 as a lamination forming section on the upstream side. It is installed. The suction device 4 is arranged to face the lower side of the air laid device 2.
In the transport direction TD, downstream from these devices 2, 3, and 4, a water jet device 5 as a water entangling unit and a drying device 6 as a dewatering / drying unit are arranged in this order from the upstream side. . A winding device 7 for winding the continuously manufactured composite nonwoven fabric CWeb is further provided downstream of the drying device 6.

The airlaid device 2 is defibrated with a defibrator 21 that disentangles (also referred to as “opening”) the raw pulp RP in which the fibers are densely packed into a sheet shape, and a blower (not shown). And a duct 22 for conveying the pulp fiber FP to the air-laid hopper 23. The air-laid hopper 23 is designed so that the defibrated pulp fiber FP descends while being dispersed in the air hopper 23 and gradually accumulates at the stacking position 24 set on the lower surface.
A suction device 4 is disposed opposite to the lower side of the stacking position 24. More specifically, the suction device 4 has a suction portion 42 on the upper surface of the device main body 41, and the suction portion 42 is set with respect to the lamination position 24 so as to apply a suction force (negative pressure) to the pulp fiber FP. It is.

Further, a transport wire 43 for transporting the web is disposed around the suction device 4. The transport wire 43 is placed so that the pulp fiber FP can be placed at the stacking position 24 and transported downstream. However, the pulp fiber FP is not placed directly on the transport wire 43. This will become clear from the following description.
The carrier wire 43 is formed in an open-mesh shape (mesh) so that the suction force of the suction part 42 extends to the opposite side (upper side).

In addition, the conventionally well-known pulp is employable as said raw material pulp RP. For example, when wood pulp is employed, NBKP such as radiata pine, slash pine, southern pine, spruce, and Douglas fir is preferable and may be appropriately selected in consideration of defibration properties, yield, and the like.
Furthermore, since the raw material pulp RP is often supplied in the form of a roll pulp as illustrated, it is preferable to employ a hammer mill, a disk mill type or the like as the defibrating device 21. The defibrating process here may be a single stage or a plurality of stages as required.
Moreover, you may make it mix | blend synthetic fibers, such as natural fibers, such as cotton, and polyester, a polypropylene, and polyethylene, with the said raw material pulp RP. When adopting such a composition, an airlaid head may be added separately to overlap the web layer, or an air feeding line for mixing other fibers may be added to a duct for airing the opened pulp.

A synthetic fiber web supply device 3 is disposed below the air laid device 2 and upstream of the suction device 4. A synthetic fiber web SW prepared in advance is set in a roll shape in the synthetic fiber web supply device 3. The synthetic fiber web SW is drawn out from the synthetic fiber web supply device 3 and is transported to the stacking position 24 on the transport wire 43 described above.
The synthetic fiber web SW is preferably a continuous filament web formed by a spunbond method. The synthetic fiber here is preferably selected from nylon, vinylon, polyester, acrylic, polyethylene, polypropylene, polystyrene and the like.

The above-described pulp fiber FP is placed (stacked) on the synthetic fiber web SW located at the stacking position 24, and the synthetic fiber web SW is conveyed downstream on the conveying wire 43.
At that time, at the stacking position 24, the suction force by the suction part 42 of the suction device 4 passes through the transport wire 43 and acts on the synthetic fiber web SW and the pulp fiber FP thereon. Therefore, the laminated web moved to the downstream side through the laminating position 24 is laminated with the lower synthetic fiber layer (synthetic fiber web SW) and the pulp fiber layer (pulp web) placed thereon. It becomes the preliminary | backup laminated body PWeb of the state which was in a state.

The above-described preliminary laminated body PWeb is maintained in a laminated state by being sucked and compressed by the suction force of the suction device 4. At this time, the upper pulp fiber layer is in a state where the pulp fibers FP are dense. However, if the preliminary laminate PWeb is conveyed and introduced into the downstream water jetting device 5 as it is, a part of the pulp fiber FP may be swollen by the water flow (water jet).
Therefore, in the present manufacturing apparatus 1, the preliminary laminated body PWeb is sandwiched from above and below, the sandwiching roller 28 for stabilizing the placement state of the pulp fiber FP on the synthetic fiber web SW, and the upstream side of the water flow injection device 5. Further, a prewetting device 30 for providing moisture to the pulp fiber FP to prevent scattering is provided. The prewetting device 30 preferably applies a suction force from the spray nozzle 31 that sprays the water mist from above the preliminary laminate PWeb and the lower side of the preliminary laminate PWeb (that is, the lower surface of the synthetic fiber web SW). And a suction device 32.

  The sandwiching roller 28 and the prewetting device 30 can be understood as a pre-processing unit for smooth execution of the water entangling process in the water jetting device 5. The pre-processing unit shown in FIG. 2 is a preferred configuration example, and the sandwiching roller 28 may be omitted.

The water jet device 5 promotes the confounding of the pulp fibers by blowing a high-pressure water jet to the preliminary laminate PWeb that has been subjected to the processing of the pretreatment units 28 and 30. Thereby, integration of the pulp fiber layer located on the upper side and the synthetic fiber layer located on the lower side is promoted.
In the water jet device 5 illustrated in FIG. 2, the water jet nozzles 51 are arranged in multiple stages (four stages illustrated in FIG. 2) along the transport direction TD. It is good also as a substitute for the pre-wet apparatus 30 mentioned above by spraying the 1st stage water-flow injection nozzle by low pressure.
In FIG. 2, the state of the nozzles in the direction perpendicular to the transport direction TD (the width direction of the apparatus 1) is not shown, but a plurality of water jet nozzles are also arranged in the width direction.

  The water pressure at the time of the hydroentanglement treatment is desirably set in consideration of the basis weight of the pulp fiber layer (web) and the synthetic fiber layer (web). For example, it is preferable to select in the range of 1 to 30 MPa.

  A suction device 52 is disposed so as to face the water jet nozzle 51. The suction force of the suction device 52 is made to act on the lower side of the synthetic fiber layer located on the lower side while blowing the high-pressure water jet from the water jet nozzle 51 to the pulp web located on the upper side. Due to the cooperative action of the water jet nozzle 51 and the suction device 52, the state where the pulp fibers of the pulp web have entered the fibers of the lower synthetic fiber web, the state where the synthetic fiber web has penetrated to the opposite side, etc. Is estimated to be formed. The action promotes the integration of the two layers.

The water jet device 5 is also provided with a transport wire 55. The transport wire 55 receives the preliminary laminate PWeb downstream of the pretreatment units 28 and 30 and transports it into the water jetting device 5. The transport wire 55 is disposed so as to pass between the water jet nozzle 51 and the suction device 52 of the water jet device 5 from the upstream side toward the downstream side.
Therefore, the preliminary laminated body PWeb transported on the transport wire 55 is subjected to more hydroentanglement processing as it goes downstream in the transport direction TD. Sufficient entanglement between the layer and the lower synthetic fiber web is achieved.
Immediately after leaving the water jetting device 5, the web is in a wet state, and before drying, the bond between the pulp fibers is not sufficiently established.

  Therefore, a drying device 6 for removing water from the wet web is disposed downstream of the water jet device 5. The drying device 6 exemplified here is preferably an air-through dryer. The rotatable dryer main body 61 is a cylindrical body, and a large number of through holes are provided on the peripheral surface thereof. Hot air heated by a heat source (not shown) is radiated from the center side of the dryer main body 61 toward the outer periphery. It is a structure that blows out. Therefore, when the wet web exits from the drying device 6, it is sufficiently dried to complete the bonding of the fibers, and the composite nonwoven fabric CWeb is completed as a product. The composite nonwoven fabric CWeb manufactured continuously in this manner is wound around the roller 71 of the winding device 7 to complete a series of steps.

The basic configuration of the production apparatus for producing the composite nonwoven fabric according to the present invention has been described above. Below, the specific structure for forming an uneven | corrugated | grooved part in a pulp fiber layer is demonstrated.
As described above, the manufacturing apparatus 1 for manufacturing the nonwoven fabric CWeb includes the water jet device 5 that performs the water flow entanglement process, and includes the water jet nozzle 51 and the suction device 52 disposed so as to face the water jet nozzle 51. In the meantime, the entangling process is realized by introducing and transporting the preliminary laminate PWeb.
The production method of the present invention produces, with a simple configuration, a nonwoven fabric CWeb in which uneven portions are formed on the pulp fiber layer on the surface as a characteristic of a wet web (raw fabric) coming out of the water jet device 5. It is an invention that makes it possible. Hereinafter, the three inventions will be described in order.

FIG. 3 is a schematic view for explaining a first method for producing a composite nonwoven fabric in which the uneven portions DE and PR are formed on the pulp fiber layer FP. FIG. 3 is an enlarged view of a partial configuration of the water jet device 5 and a peripheral portion related thereto. Specifically, a plurality of water jet nozzles 510 disposed in a direction perpendicular to the transport direction TD, the transport wire 55, and the suction device 52 disposed on the lower side of the transport wire 55 and the transport wire 55 are placed on the transport wire 55. FIG. 3 schematically shows the state of the preliminary laminate PWeb.
In the configuration shown in FIG. 3, the nozzle diameter of the water jet nozzle 510 is set to 0.15 to 0.25 mm, for example. A typical conventional water jet nozzle has a smaller diameter than the water jet nozzle 510 and has a nozzle diameter of 0.05 to 0.15 mm, for example. Since the amount of jet water is proportional to the square of the nozzle diameter, the water jet nozzle 510 can discharge more water than before.
As will be described later, when water entanglement is performed using a water jet nozzle 510 having a larger diameter (larger diameter) than a conventional one and a conventional water jet nozzle in combination, the water jet nozzle 510 is a conventional water jet nozzle. The diameter is preferably set to 1.2 to 2.0 times the diameter. In view of the diameter of the water jet nozzle 510 as a reference, it is preferable to use a conventional water jet nozzle having a small diameter of 0.5 to 0.83 times the diameter.
The water pressure of the water jet nozzle is desirably 1 to 30 MPa as described above, and when the water jet nozzle 510 having a relatively large diameter is employed, the arrangement pitch is widened compared to the conventional case, What is necessary is just to reduce and set the number of arrangement.

  Generally, since the suction device 52 is disposed below the synthetic fiber SW, the water flow from the water jet nozzle is passed through the preliminary laminate PWeb while removing excess water, so that this water flow is adjusted. The fibers can be entangled with each other. At that time, in the present invention, the water jet nozzle 510 employs a nozzle having a larger diameter (thickness) than the conventional one, so that the pulp fiber layer FP at the center of the water stream is repelled (repelled) or removed. Arise. More specifically, the suction device 52 is disposed below the water jet nozzle 510. However, in the case of a water flow that is thicker than the conventional one, it cannot be partially supported by the suction force from below. Thereby, a concave shape is formed at a position corresponding to the water jet nozzle 510 in the pulp fiber layer FP having relatively low rigidity on the upper side of the preliminary laminate PWeb. And since the preliminary | backup laminated body PWeb is conveyed on the conveyance wire 55 in the conveyance direction TD, as shown in FIG. 3, several streak-like uneven parts (concave part DE, convex part PR) are formed toward the downstream. Will be.

  The water jet nozzle 510 according to FIG. 3 is larger than the conventional water jet nozzle, is reduced in number compared to the conventional water jet nozzle, and is arranged with a wide interval. This interval corresponds to the interval between the recesses DE, and the projection PR is formed therebetween. FIG. 3 schematically shows the state of the pulp fiber layer FP so that the invention can be easily understood.

As shown in FIG. 2, the water jet nozzle 51 and the suction device 52 in the water jet device 5 are formed in multiple stages along the transport direction TD (illustrated in FIG. 2 is four stages).
Even when the invention according to FIG. 3 is carried out, the water jet nozzles 510 are arranged in multiple stages as shown in FIG. 2, and the water jet by the water jet nozzles 510 is repeatedly sprayed toward the same position of the preliminary laminate PWeb. Thus, the recess DE can be reliably formed. Of course, the number of stages of the water jet nozzles 510 may be arbitrarily set as necessary in order to ensure the formation of the recess DE. In this case, it is preferable that the equipment can finely adjust the position of the nozzle.

By the way, when the water jet nozzles have four stages as in the embodiment shown in FIG. 2, it is preferable to perform the following process.
The first water jet nozzle 51 in the first stage is a conventional type (having a smaller diameter than the water jet nozzle 510 in FIG. 3), and the water entanglement in which a water jet is blown toward the entire surface of the pulp fiber layer FP. The treatment (first hydroentanglement) is performed and the entire pulp fiber is entangled.
Next, with respect to the second and third stage water jet nozzles 51, an uneven portion is formed using the water jet nozzle 510 having a large diameter with the nozzle diameter described in FIG. 3 being 0.15 to 0.25 mm. The water entanglement process (2nd water entanglement process) for performing is performed.
For the final fourth stage water jet nozzle 51, the water jet is directed toward the entire surface of the pulp fiber layer FP using the conventional small diameter water jet nozzle as in the first first stage. It is more preferable to perform the hydroentanglement process of spraying.

As described above, when the first hydroentanglement process, which is a conventional hydroentanglement process, is performed at the beginning and the end, it is possible to prevent the initial unfixed fibers from being scattered, thereby forming a clearer pattern. Can do. And since the entanglement of the pulp fiber layer FP and the synthetic fiber SW can be finally performed as a whole, a stronger composite type nonwoven fabric CWeb can be obtained.
If the second hydroentanglement process (a hydroentanglement process with a large nozzle diameter) is performed first, unentangled pulp fibers may be scattered by the large diameter nozzle. There is a concern that it will be disturbed. In addition, it is not preferable to end the second hydroentanglement process. This is because the entanglement of the pulp fibers moved to the convex part remains in an insufficient state, and the entanglement is not completed as the whole web.

  FIG. 4 is a diagram shown for explaining the second method. FIG. 4 also shows a partial configuration of the water jet device 5 and a peripheral portion related thereto in an enlarged manner. A plurality of water jet nozzles 51 disposed in a direction perpendicular to the transport direction TD, a transport wire 55, a suction device 52 disposed below the transport wire 55, and the preliminary laminate PWeb placed on the transport wire 55 4 is the same as FIG. 3 in that FIG.

Here, the description will focus on differences from the first method. In the suction device 52 shown in FIG. 4, an impermeable portion 521 is provided in an opening 520 provided for applying a suction force. This impermeable portion 521 functions as a baffle plate arranged so that suction force does not act. A plurality of impermeable parts 521 are arranged at intervals in a direction perpendicular to the transport direction TD. In the portion where the water-impermeable portion 521 exists, the suction force does not act on the preliminary laminate PWeb. On the other hand, a suction force acts on a portion where the impermeable portion 521 does not exist. As a result, a state in which the pulp fibers escape (turn around) is formed on both sides of the impermeable portion 521 on which the suction force is acting. As a result, the pulp fiber layer at the position corresponding to the impermeable portion 521 becomes the concave portion DE, and the pulp fiber layer at the position where the suction force acts between the impermeable portions 521 becomes the convex portion PR.
The impermeable portion 521 that is preferable for forming the concave portion DE has a width of, for example, 1 mm or more, and is preferably set as an interval of 3 to 5 mm.
The suction force (negative pressure) by the suction device 52 is preferably 0.01 to 0.05 (Mpa), for example. Here, 0.01 MPa is equal to 100 mbar or 75 mmHg.

In the case of FIG. 4 as well, in the same way as in FIG. 3, the suction devices 52 in which the impermeable portions 521 are formed at the same position are arranged in multiple stages in the transport direction TD so as to reliably form the uneven portions. Is preferred.
And about the suction device 52 located in the beginning and the last, the impermeable part 521 is not provided, but the whole entangling of the pulp fiber layer FP and the synthetic fiber SW is performed by applying a suction force to the entire preliminary laminate PWeb. It is preferable to realize it. This point is the same as that in the first manufacturing method shown in FIG. 3, the water jet is finally sprayed on the entire surface of the pulp fiber layer FP.
Note that the water jet nozzle 51 illustrated in FIG. 4 is a conventional type, and the nozzle diameter may be 0.05 to 0.15 mm, and a water jet may be sprayed over the entire surface of the pulp fiber layer FP.
As described above, the composite nonwoven fabric in which the uneven portion is formed on the surface of the pulp fiber layer can also be manufactured by the manufacturing method using the suction device 52 shown in FIG.

Further, the third manufacturing method will be described. Conventionally, a conveying wire is generally configured by arranging a plurality of warp yarns and weft yarns in a mesh shape (mesh shape) and yarns having the same thickness. In the third manufacturing method, a composite nonwoven fabric is manufactured by performing hydroentanglement processing using a new transport wire different from the transport wire of the general concept.
FIG. 5 shows an enlarged view of a part of an example of the transport wire 550 that can be employed in the third manufacturing method. The transport wire 550 is provided with warp yarns 551B having a diameter larger than that of other warp yarns for every predetermined number (for example, every five yarns) of the plurality of warp yarns 551. Note that the warp 551 is parallel to the transport direction TD.

Similarly, a weft yarn 552B having a diameter larger than that of the other weft yarns is arranged for each predetermined number of the weft yarns 552 (every five in the example) among the plurality of weft yarns 552.
Here, the warp yarn 551 and the weft yarn 552 of the transport wire 550 have a general diameter of 0.2 to 0.6 mm. However, the thick warp yarn 551B and the thick warp yarn 551B preferably have a diameter of 1 mm or more, for example. Alternatively, it is preferable to set the diameter of the thick yarn to be 3 to 5 times, for example, compared to the diameter of other yarns. Thereby, an uneven | corrugated | grooved part can be reliably formed in the surface of a pulp fiber layer. In this case, the respective opening ratios of the warp and the weft are preferably 10% or more, and more preferably 20 to 30%. The aperture ratio (%) here is defined based on the number of yarns existing within 1 cm and the diameter of the yarns. Specifically, the aperture ratio (%) can be calculated by the formula [(1−number of yarns × yarn diameter) / 1] × 100 (%).

When the hydroentanglement process is performed by the water jet device 5 using the transport wire 550 as described above, a concave portion is formed in the pulp fiber layer at a position corresponding to the position (region) where the thick yarn is present. Since the action of the suction force on the pulp fiber layer existing on the thick yarn is limited, a state in which the pulp fiber escapes (turns around) to both sides where the suction force is applied is formed. As a result, convex portions are formed in the pulp fiber layer on both sides of the thick yarn, and concave portions are formed corresponding to positions where the thick yarn is present.
As explained above, by devising the carrier wire used for the water jetting device 5, a composite nonwoven fabric in which uneven portions are formed on the pulp fiber layer can be produced.

The conveying wire 550 shown in FIG. 5 illustrates the case where thick yarns are arranged in both the vertical and horizontal directions. When this conveying wire 550 is used, the uneven portions in the form of vertical and horizontal lattices are pulp. It is formed on the surface of the fiber layer.
When a thick yarn is disposed only on the warp yarn side with the transport wire 550, streaky irregularities along the transport direction TD can be formed on the surface of the pulp fiber layer as in the first and second manufacturing methods described above. .
Contrary to the above, when a thick yarn is arranged only on the weft side with the transport wire 550, it is along the direction perpendicular to the transport direction TD, which cannot be produced by the first and second manufacturing methods described above (at right angles). Streaky irregularities (parallel to the direction) can also be formed on the surface of the pulp fiber layer.
Note that the arrangement of the yarns in FIG. 5 is merely an example. When the conveying wire 550 is manufactured by a knitting machine, the manufacturing process becomes extremely troublesome if the weft is changed every predetermined number. Therefore, all the weft yarns may be the aforementioned thick yarns. In this case, since the thick yarns are arranged at a predetermined interval, convex portions are formed on the surface of the pulp fiber layer corresponding to the positions corresponding to the thick yarns.

According to the first to third manufacturing methods described above, a composite nonwoven fabric in which an uneven portion is formed on the surface of the pulp fiber layer can be manufactured only by making a simple change to the basic nonwoven fabric manufacturing apparatus.
In the description of the first to third manufacturing methods, the case where the uneven portions are repeated in the same pattern is illustrated, but this is merely an example. Depending on the non-woven fabric product requirements, the concave and convex portions may have the same width or different widths, and there may be cases where it is desired to manufacture a non-woven fabric that is designed with irregularly modified concave and convex portions. is there. In such a case, the position and arrangement of the thick threads (551B, 552B) in the water jet nozzle (510), the water-impermeable portion (521), and the transport wire (550) described above are appropriately changed. That's fine.
Furthermore, although the 1st, 2nd, 3rd manufacturing method was demonstrated separately in the above, you may manufacture a composite type nonwoven fabric which has an uneven | corrugated | grooved part on the surface of a pulp fiber layer by combining these suitably as needed. . By producing by combining the methods, more prominent irregularities can be formed in the pulp fiber layer.

  Although the description of the embodiment has been completed above, the present invention is not limited to the above-described embodiment, and it is needless to say that various modifications can be made without departing from the scope of the invention.

DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus of composite type nonwoven fabric 2 Airlaid apparatus 3 Synthetic fiber web supply apparatus 4 Suction apparatus 5 Water jet apparatus 6 Drying apparatus 7 Winding apparatus 21 Defibration machine 22 Duct 23 Airlaid hopper 24 Lamination position 28 Nipping roller 30 Prewetting apparatus 31 Spraying Nozzle 32 Suction device 41 Suction device main body 42 Suction unit 43 Conveying wire 51 Water jet nozzle 52 Suction device 55 Conveying wire 510 Water jet nozzle 520 Opening 521 Impervious portion 550 Conveying wire 551 Warp yarn 551B Thick warp 552 Weft yarn 552B Thick weft FP Fiber (pulp fiber layer)
PWeb Preliminary laminate CWeb laminate (composite type nonwoven fabric)
SW Synthetic fiber web (synthetic fiber layer)
DE Concave part of pulp fiber layer PR Convex part of pulp fiber layer

Claims (10)

A composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer,
A composite nonwoven fabric, wherein an uneven portion is formed on the surface of the pulp fiber layer.   The composite nonwoven fabric according to claim 1, wherein a plurality of the concavo-convex portions are formed in a line shape.   2. The composite nonwoven fabric according to claim 1, wherein a plurality of the uneven portions are formed in a vertical and horizontal lattice shape.   4. The composite nonwoven fabric according to claim 2, wherein the uneven portion has a height difference between the bottom of the concave portion and the top of the convex portion of 200 to 800 μm. A method of manufacturing a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer,
A water jet is blown toward the preliminary laminate formed by the synthetic fiber layer and the pulp fiber placed on the synthetic fiber layer to perform hydroentanglement treatment, and the pulp fiber layer and the synthetic fiber layer are synthesized. Including at least a hydroentanglement process that promotes integration with the fiber layer;
In the hydroentanglement step, the preliminary laminate is transported by being placed on a transport wire, and the water jet is sprayed toward the pulp fiber layer from a plurality of water spray nozzles arranged in a direction perpendicular to the transport direction. Suction is performed with a suction device disposed below the transport wire, and a plurality of streaky irregularities are formed on the surface of the pulp fiber layer with the position corresponding to the water jet nozzle as a recess. A method for producing a composite nonwoven fabric.   The plurality of water jet nozzles have a nozzle diameter of 0.15 to 0.25 mm, and the plurality of water jet nozzles are arranged in a plurality of stages along the transport direction. A method for producing a composite nonwoven fabric.   Before and after the second hydroentanglement process by the multi-stage water jet nozzle, a water jet is blown toward the entire surface of the pulp fiber layer using a water jet nozzle having a diameter smaller than that of the multi-stage water jet nozzle. The method for producing a composite nonwoven fabric according to claim 6, wherein the first hydroentanglement process is performed. A method of manufacturing a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer,
A water jet is blown toward the preliminary laminate formed by the synthetic fiber layer and the pulp fiber placed on the synthetic fiber layer to perform hydroentanglement treatment, and the pulp fiber layer and the synthetic fiber layer are synthesized. Including at least a hydroentanglement process that promotes integration with the fiber layer;
In the hydroentanglement step, the preliminary laminate is transported by being placed on a transport wire, and the water jet is sprayed toward the pulp fiber layer from a plurality of water spray nozzles arranged in a direction perpendicular to the transport direction. , Suction with a suction device arranged below the conveying wire,
By arranging a plurality of impermeable parts along the direction perpendicular to the conveying direction in the suction device, and by forming a plurality of recesses on the surface of the pulp fiber layer corresponding to the position of the impermeable parts, The manufacturing method of the composite type nonwoven fabric characterized by forming a several streaky uneven | corrugated | grooved part. A method of manufacturing a composite nonwoven fabric in which a pulp fiber layer is laminated and integrated on a synthetic fiber layer,
A water jet is blown toward the preliminary laminate formed by the synthetic fiber layer and the pulp fiber placed on the synthetic fiber layer to perform hydroentanglement treatment, and the pulp fiber layer and the synthetic fiber layer are synthesized. Including at least a hydroentanglement process that promotes integration with the fiber layer;
In the hydroentanglement step, the preliminary laminate is transported by being placed on a transport wire, and the water jet is sprayed toward the pulp fiber layer from a plurality of water spray nozzles arranged in a direction perpendicular to the transport direction. , Suction with a suction device arranged below the conveying wire,
The transport wire is formed by a plurality of warp yarns and weft yarns, and has at least one of the warp yarns and the weft yarns, and has a form in which a plurality of thick yarns having a diameter larger than other yarns are arranged at intervals. By forming a plurality of recesses on the surface of the pulp fiber layer corresponding to the position of the thick yarn, a plurality of streaky irregularities or a plurality of vertical and horizontal lattice-shaped irregularities are formed. Nonwoven fabric manufacturing method.   The manufacturing method which manufactures the said composite type nonwoven fabric by combining 2 or more from the manufacturing method of Claim 5, Claim 8, and Claim 9.

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