JP4446579B2 - Perforated nonwoven fabric and method for producing the same - Google Patents
Perforated nonwoven fabric and method for producing the same Download PDFInfo
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Description
【０００１】
【発明の属する技術分野】
本発明は、優れた柔軟性と優れた耐摩耗性とを兼ね備えた、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに用いられ、特にふき取り布に好適な開孔不織布及びその製造法に関する。
【０００２】
【従来の技術】
柔軟性があり、強度のある不織布として、水流絡合により繊維間を交絡させ熱接着性繊維によって繊維交点を接着させた様々な不織布が、従来より提案されている。たとえば、特開平１０−２３７７５１号公報には、潜在捲縮性複合繊維２０〜５０％と非熱接着繊維８０〜５０％からなるウエブを、水流絡合により繊維を交絡させ、熱処理を施して、潜在捲縮複合繊維の捲縮を発現すると同時に低融点成分を熱接着させた、柔軟性と触感に優れた不織布が提案されている。しかし、この不織布は開孔していないため、拭き取り性や通気性や通水性に劣るものであった。また、特開平９−３０２５６２号公報には、高圧流体流の作用により繊維同士が交絡し、かつ繊維が再配列されて開孔が形成された不織布が、横方向に伸長されてなる開孔不織布であって、熱可塑性繊維の一部が熱融着している開孔不織布が提案されている。しかし、このような不織布は、ドレープ性の向上と横方向の強度向上はみられるものの、熱融着した熱可塑性繊維の比率が少ない場合は繊維の抜けが多く耐摩耗性に劣り、熱融着した熱可塑性繊維の比率が多い場合は、風合いが硬く柔軟性に劣るものであった。さらに開孔不織布を生産するに際して、開孔形成用支持体より開孔不織布を剥離する際に、開孔形成用支持体に一部絡んでいた繊維が引っ張られ、開孔形成用支持体に接した面で毛羽が発生してしまうという問題があった。そして、このような開孔不織布を、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材等に用いると毛羽の多い面が耐摩耗性に劣るという問題があった。また、この発生した毛羽を止めるため、開孔不織布全体の接着性繊維の比率を多くすると、風合いが硬くなり、柔軟性に劣ってしまうという問題があった。
【０００３】
【発明が解決しようとする課題】
本発明は、上記のような問題点を解決するためになされたものであり、相反する特性である優れた柔軟性と優れた耐摩耗性とを兼ねそなえた、しかも両面ともに耐摩耗性に優れた、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに用いられ、特にふき取り布に好適な開孔不織布及びその製造法を提供することを課題とする。
【０００４】
【課題を解決するための手段】
請求項１の発明は、接着性繊維５〜３０重量％と該接着性繊維以外の繊維７０〜９５重量％からなり、繊維が３次元的に絡合された開孔不織布であって、該開孔不織布の表面層と裏面層において該接着性繊維の重量比率が５％以上異なり、かつ該表面層と該裏面層において該接着性繊維が繊維接着していることを特徴とする開孔不織布である。すなわち、本発明では繊維が３次元的に絡合されているため、風合いが柔軟であり拭き取り布などとしての実用的な強度のある繊維構造物となっており、さらに繊維間が接着性繊維によって接着されているため耐摩耗性のある繊維構造物となっている。また、前記接着性繊維は前記繊維構造物全体の５〜３０重量％であるため前記接着性繊維の熱接着による風合いの変化は大きくなく実用に適合した柔軟な風合いが維持できる。また、前記繊維構造物は水流の作用等によって繊維配向を変えられて作られた表面から裏面に貫通する開孔を有しているため、拭き取り性、通気性、通水性に優れた構造となっている。さらに本発明では、水流の作用により繊維が３次元的に絡合される際に、前記繊維構造物において毛羽が多くでる面側、すなわち開孔形成用支持体に接する面側に属する層（表面層または裏面層）に含まれる接着性繊維の重量比率が反対面に属する層（裏面層または表面層）に含まれる接着性繊維の重量比率よりも５％以上多くなっているため、開孔形成用支持体に接する面である、毛羽が多くでる面での毛羽立ちが防止され耐摩耗性が向上し、他の面と同様の耐摩耗性を示すことができる。また前記繊維構造物において１本の繊維に注目すると、この繊維は３次元的に絡合されているため、表面層と裏面層の両層において他の繊維と交絡点を持っている。そして、毛羽が多くでる面側に属する層では接着性繊維との交絡点において接着が充分に行われるため、繊維の抜けが起こりにくくなる。その結果、前記繊維構造物は毛羽が多くでる面の反対面においても繊維の抜けが起こりにくくなり、良好な耐摩耗性を呈することができる。そしてまた、毛羽が多くでる面の反対面に属する層に含まれる接着繊維の重量比率が毛羽が多くでる面に属する層より５％以上少ないため、反対面も接着繊維が同じ重量比率である場合と比較して、前記繊維構造物全体の接着点は少なくなり、前記繊維構造物はより柔軟な風合となる。このように、本発明では、接着点を多く持つ層を片面に偏在させることによって、偏在させない場合の耐摩耗性と同等の耐摩耗性を両面ともに保ちながら、風合いをさらに柔軟にすることができるため、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに好適な開孔不織布を提供することができる。また、本発明の開孔不織布をふき取り布に用いると、開孔部分にゴミを補足することができ、また開孔不織布とふき取りされる面との間の接触面積が少なくなるので、摩擦による抵抗が少なくふき取り易い。このため本発明の開孔不織布は特にふき取り布に好適である。
【０００５】
請求項２の発明は、接着性繊維が５〜２０重量％と該接着性繊維以外の繊維が８０〜９５重量％からなることを特徴とする請求項１に記載の開孔不織布であり、請求項１に記載の開孔不織布において、接着性繊維を５〜２０重量％とすることにより、特に柔軟性に優れた開孔不織布を得ることができる。
【０００６】
請求項３の発明は、接着性繊維が潜在捲縮性繊維であることを特徴とする請求項１または２に記載の開孔不織布である。すなわち、請求項１または２に記載の開孔不織布において、例えば、芯鞘タイプの複合繊維で、鞘部分が芯部分より低融点の重合体であり、加熱処理により捲縮を発現するのみならず鞘部分が他の繊維と接着するような繊維を用いることによって、接着性繊維としての働きにより、請求項１または２に記載の開孔不織布を得ることができるとともに、捲縮発現により毛羽立ち防止の効果があるため、特に毛羽立ちの少ない開孔不織布を得ることができる。
【０００７】
請求項４の発明は、親水性繊維を３０重量％以上含むことを特徴とする請求項１〜３のいずれかに記載の開孔不織布であり、請求項１〜３のいずれかに記載の開孔不織布において、親水性繊維を３０重量％以上含むことにより、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などの用途のうち特に親水性の要求される場合に好適な開孔不織布を得ることができる。
【０００８】
請求項５の発明は、絡合が水流絡合法によるものである請求項１〜４のいずれかに記載の開孔不織布であり、請求項１〜４のいずれかに記載の開孔不織布において、絡合を水流絡合法によって形成することにより、絡合と同時に開孔を形成することができ、またニードルパンチ法では得ることのできない重量の低い開孔不織布を得ることができる。
【０００９】
請求項６の発明は、接着性繊維と該接着性繊維以外の繊維からなる繊維ウエブＡと、繊維ウエブＡよりも接着性繊維の重量比率が５％以上少ない繊維ウエブＢとを形成するに際して、繊維ウエブＡと繊維ウエブＢとに含まれる合計の繊維に対して、該接着性繊維が５〜３０重量％及び該接着性繊維以外の繊維が７０〜９５重量％となるように形成した後、繊維ウエブＡが最下層に、繊維ウエブＢが最上層になるように、開孔形成用支持体の上に繊維ウエブを積層載置した後、積層した繊維ウエブに水流処理により積層した繊維ウエブを絡合及び開孔させた後、該接着性繊維の繊維接着処理を行う開孔不織布の製造方法であり、絡合と開孔により開孔不織布に柔軟性を与え、さらに繊維接着処理により繊維の抜けを防ぎ開孔不織布の耐摩耗性を向上させることができる。また、開孔形成用支持体より剥離する際に生じた、繊維ウエブＡから発生した毛羽は、繊維ウエブＡ中の接着性繊維の配合比率が多いため、充分に押さえることができる。また、接着性繊維は片面のみが多くなっているので開孔不織布全体が硬くなることはない。このように、接着点を多く持つ層を片面に偏在させることによって、偏在させない場合の耐摩耗性と同等の耐摩耗性を両面ともに保ちながら、偏在させない場合よりも風合いを柔軟にする効果を得ることができるため、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに好適な開孔不織布を提供することができる。また、本発明の開孔不織布をふき取り布に用いると、開孔部分にゴミを補足することができ、また開孔不織布とふき取りされる面との間の接触面積が少なくなるので、摩擦による抵抗が少なくふき取り易い。このため本発明の開孔不織布は特にふき取り布に好適である。
【００１０】
【発明の実施の形態】
本発明は、接着性繊維５〜３０重量％と該接着性繊維以外の繊維７０〜９５重量％からなり、繊維が３次元的に絡合された開孔不織布であって、該開孔不織布の表面層と裏面層において該接着性繊維の重量比率が５％以上異なり、かつ該表面層と該裏面層において該接着性繊維が繊維接着していることを特徴とする開孔不織布である。
【００１１】
また本発明は、接着性繊維と該接着性繊維以外の繊維からなる繊維ウエブＡと、繊維ウエブＡよりも接着性繊維の重量比率が５％以上少ない繊維ウエブＢとを形成するに際して、繊維ウエブＡと繊維ウエブＢとに含まれる合計の繊維に対して、該接着性繊維が５〜３０重量％及び該接着性繊維以外の繊維が７０〜９５重量％となるように形成した後、繊維ウエブＡが最下層に、繊維ウエブＢが最上層になるように、開孔形成用支持体の上に繊維ウエブを積層載置した後、積層した繊維ウエブに水流処理により積層した繊維ウエブを絡合及び開孔させた後、該接着性繊維の繊維接着処理を行う開孔不織布の製造方法である。
【００１２】
本発明に使用する接着性繊維は、該接着性繊維以外の繊維よりも好ましくは１０°Ｃ以上低い融点で溶融する繊維であり、１種類の熱可塑性樹脂からなる合成繊維か、または融点が好ましくは１０°Ｃ以上異なる２種類以上の樹脂が複合された複合繊維であって、繊維の表面に該接着性繊維以外の繊維よりも低い融点で溶融する樹脂を有する複合繊維が好ましく、このような接着性繊維を加熱した時、該接着性繊維の少なくとも一部が８０°Ｃ以上、好ましくは１００°Ｃ以上で溶融する繊維が適している。１種類の熱可塑性樹脂からなる合成繊維としては、例えばポリオレフィン繊維、ポリエステル繊維、ポリアミド繊維、アクリル繊維などの熱可塑性樹脂からなる合成繊維がある。また融点の異なる２種類以上の樹脂が複合された複合繊維としては、例えば、共重合ポリエステル／ポリエステル、共重合ポリプロピレン／ポリプロピレン、ポリプロピレン／ポリアミド、ポリエチレン／ポリプロピレン、ポリプロピレン／ポリエステル、ポリエチレン／ポリエステルなどの樹脂の組み合わせからなる複合繊維がある。
【００１３】
また、本発明に使用する接着性繊維は、上記の複合繊維であるとともに潜在捲縮性繊維であることがさらに好ましい。このような潜在捲縮性を併せ持つ複合繊維としては、例えば温度特性の異なる複数の樹脂成分から成る芯鞘型もしくはサイドバイサイド型といった複合構造を有する繊維であって、樹脂成分中の１成分と他の樹脂成分との間で熱収縮率及び溶融温度が、異なる組み合わせとなっており、１つの樹脂成分が軟化して収縮し、しかも他の樹脂成分が実質的に収縮しない温度で熱処理を施すことによって、個々の繊維がコイル状（または、スパイラル状）の捲縮を持つようになる複合繊維であり、さらに、この複合繊維は樹脂成分中の１成分の溶融する温度まで熱処理を行えば接着繊維としても用いることができる複合繊維をあげることができる。このような複合繊維は、最適な捲縮発現条件を選んだ場合に、外力がかからない状態で発現後の捲縮数が発現前の室温での捲縮数の少なくとも２倍以上に増加するものが望ましく、例えば、室温で１０〜２０個／インチの捲縮数が、繊維単独で外力がかからない状態で１１０〜１７０℃で１５分間加熱した場合に、４０〜２００個／インチ程度に増加するものが好ましい。
【００１４】
このような接着性と潜在捲縮性を併せ持つ複合繊維としては、例えば、共重合ポリエステル／ポリエステル、共重合ポリプロピレン／ポリプロピレン、ポリプロピレン／ポリアミド、ポリエチレン／ポリプロピレン、ポリプロピレン／ポリエステル、ポリエチレン／ポリエステルなどの樹脂の組み合わせからなる複合繊維がある。このような複合繊維を加熱処理して捲縮を発現させると、接着性繊維としての働きにより、本発明による開孔不織布を得ることができるとともに、捲縮発現による毛羽立ち防止の効果が生じて、特に毛羽立ちの少ない開孔不織布を得ることができる。
【００１５】
本発明に使用する接着性繊維以外の繊維は、該接着性繊維を構成する樹脂のうち接着成分となる樹脂の融点より、好ましくは１０°Ｃ以上高い融点で溶融する樹脂または成分から構成された繊維であり、合成繊維や半合成繊維や天然繊維など繊維の種類は問わず適宜選択できる。このような接着性繊維以外の繊維は、合成繊維の場合は、１種類の熱可塑性樹脂からなる合成繊維であっても、異なる２種類以上の樹脂が複合された複合繊維であっても適宜選択して使用することができる。
【００１６】
本発明に使用する親水性繊維は、水に対して濡れ性の良い繊維が好ましく、吸水性の優れたものは特に好ましく、合成繊維や半合成繊維や天然繊維など繊維の種類は問わず適宜選択できる。このような親水性繊維としては、例えばレーヨン繊維、コットン繊維、アセテート繊維、アクリル繊維などがある。本発明では、このような親水性繊維を３０重量％以上含むことにより、特に親水性の要求される、ふき取り布、おむつ部材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに好適な開孔不織布を得ることができる。
【００１７】
本発明の開孔不織布では、接着性繊維５〜３０重量％と該接着性繊維以外の繊維７０〜９５重量％からなる必要があるが、接着性繊維５〜２０重量％と該接着性繊維以外の繊維８０〜９５重量％からなる場合、柔軟性と耐摩耗性がともに優れ、好適である。接着性繊維が５重量％未満である場合は、実用的な強度が不足し、毛羽止めも不充分であり、また耐摩耗性のある開孔不織布を得ることはできない。また接着性繊維が３０重量％を超えると、風合いが硬くなり、本発明が目標とする各用途における柔軟性の要求を満たすことができない。
【００１８】
本発明の開孔不織布は、親水性繊維を３０重量％以上含むことが望ましく、特に親水性の要求される、ふき取り布、おむつ部材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに好適な開孔不織布を得ることができる。
【００１９】
本発明の開孔不織布は、表面層と裏面層において該接着性繊維の重量比率が５％以上異なる必要がある。すなわち開孔形成用支持体に接する面側に属する層（表面層または裏面層）に含まれる接着性繊維の重量比率が反対面に属する層（裏面層または表面層）に含まれる接着性繊維の重量比率よりも５％以上多くなっていると、開孔形成用支持体に接する面である、毛羽が多くでる面での毛羽立ちが防止され耐摩耗性が向上し、他の面と同様の耐摩耗性を示すことができる。もし重量比率の差を５％より少なくして、しかも耐摩耗性を両面同等にしようとすると、開孔不織布中に含まれる接着繊維の重量比率が必要以上に多くなってしまい、風合いが硬くなり、本発明が目標とする各用途における柔軟性の要求を満たすことができない。
【００２０】
本発明では、繊維層を積層する方法は、公知の乾式法、湿式法、溶融紡糸法等のいずれかの繊維ウエブ形成法により積層するか、これらの方式を組み合わせて積層することができる。繊維ウエブを積層するに際しては、接着性繊維５重量％以上からなる繊維ウエブを繊維ウエブＡとし、接着性繊維５重量％以上からなる繊維ウエブであって、繊維ウエブＡよりも接着性繊維の重量比率が５％以上少ない繊維ウエブを繊維ウエブＢとすると、繊維ウエブＡと繊維ウエブＢに含まれる合計の繊維に対して、該接着性繊維が５〜３０重量％及び該接着性繊維以外の繊維が７０〜９５重量％となるように繊維ウエブを積層する方法が望ましい。また、繊維ウエブＡは接着性繊維２０〜３０重量％と該接着性繊維以外の繊維８０〜７０重量％からなるのが好適であり、繊維ウエブＢは接着性繊維５〜１５重量％と該接着性繊維以外の繊維９５〜８５重量％からなるのが好適である。
【００２１】
本発明では、積層した繊維層に絡合処理と開孔処理を行う方法には、水流絡合法等における流体流により絡合と開孔を同時に行う方法や、ニードルパンチ法等により絡合させた後、例えば先の尖ったロールとブラシロールの間に絡合された繊維層を通して繊維の配向を変えながら開孔する方法等があるが、高速生産可能な水流絡合法が好適である。
【００２２】
水流絡合法による場合は、前記繊維ウエブＡが最下層に、前記繊維ウエブＢが最上層なるように積層した繊維層を開孔形成用支持体の上に載置する。開孔形成用支持体は、金属またはプラスチックのネットからなるコンベアーベルトや前記ネットを巻いた水透過性のドラムを用いるか、または金属、プラスチックでできた孔の開いた水透過性のドラム等を用いることができる。ネットの場合は、平織り、綾織り等各種の織り構造のネットを用いることができ、５〜６０メッシュの織り組織が適しているが、特に柔軟な風合いを得るには５〜３０メッシュが適している。もし、６０メッシュを超える織り組織を用いた場合は、開孔した不織布を形成するのが困難となる。また、孔開きドラムを用いる場合は開孔面積率が１０〜８０％の孔開きドラムが適している。
【００２３】
次に、開孔形成用支持体上に載置した繊維層の上部より高速水流を噴射して、繊維層を絡合させるとともに開孔した繊維構造物を形成する。高速水流の発生には、水圧３〜２０ＭＰａの高圧水を、直径０．１〜０．３ｍｍのノズル孔が０．３〜３ｍｍ間隔で配列した１本または複数本のノズルプレートより噴射させて、高速水流とする方法が適している。
【００２４】
尚、上記の水流絡合法による開孔処理において、上記繊維層を上記開孔形成用支持体とは別の開孔のある支持体の上に載置して、予め高速水流で予備的な絡合処理を行ってから、上記の水流絡合による開孔処理を行ってもよい。この予備的処理に用いる開孔のある支持体は、上記開孔形成用支持体のメッシュや、開孔面積率の値にこだわらず、任意の開孔のある支持体を選択して用いることができる。また、この予備的な絡合処理では、上記繊維層を開孔のある支持体の上に載置するに際して上記繊維ウエブＡが最上層になっても、最下層になっても、どちらでも可能である。但し、この予備的な絡合処理では、高速水流の噴射前の圧力は、予備処理後に開孔を形成させる時の圧力よりも低くするのが望ましく、またノズルプレートの使用本数を少なくするのが望ましい。
【００２５】
本発明では、繊維層に絡合処理と開孔処理を行った後、形成された繊維構造物に含まれる接着性繊維による繊維接着処理を行う。繊維接着処理は実質的に凹凸のないコンベアー上に繊維構造物を載置して熱風を吹き付ける方法や、実質的に凹凸のないコンベアーまたはドラム状の支持体の上に載置した後に熱風を繊維構造物とその支持体を通過させる方法や、加熱したドラム状の支持体の上に繊維構造物を載置する方法等によって行うことが望ましい。
【００２６】
このようにして形成された開孔不織布の開孔は、繊維構造物の表面から裏面まで貫通していている部分の面積が全表面の１０〜８０％であるのが好適であり、１０〜５０％が最適である。１０％未満では風合いが硬く、８０％を超えると形態安定性を失うので好ましくない。
【００２７】
以上のようにして形成された開孔不織布は、絡合と開孔による柔軟性保持効果と繊維接着処理による耐摩耗性の向上効果に加えて、接着点を多く持つ層を片面に偏在させることによって、偏在させない場合の耐摩耗性と同等の耐摩耗性を両面ともに保ちながら、風合いをさらに柔軟にする効果を得ることができるため、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに好適な開孔不織布を提供することができる。また、本発明の開孔不織布をふき取り布に用いると、開孔部分にゴミを補足することができ、また開孔不織布とふき取りされる面との間の接触面積が少なくなるので、摩擦による抵抗が少なくふき取り易い。このため本発明の開孔不織布は特にふき取り布に好適である。
【００２８】
つぎに、実施例及び比較例により本発明を具体的に説明するが、この実施例は本発明が理解できる程度に特定の条件を例示して説明するものであって、本発明はこの実施例に限定されるものではない。尚、実施例及び比較例の柔軟性、耐摩耗性、引張強度、引張伸度に関する評価には次の試験方法を使用した。
（剛軟度）
得られた不織布より、２０ｍｍＸ２００ｍｍの試験片をタテ方向及びヨコ方向にそれぞれ３枚採取し、ＪＩＳ Ｌ１０９６（一般織物試験方法）の６．１９．１Ａ法（４５°カンチレバー法）に準じて剛軟度の測定を行い、タテ方向及びヨコ方向の測定値のそれぞれの平均値を求め、これらの平均値をさらに平均して剛軟度とした。本発明の開孔不織布が目的とする用途に要求される剛軟度は、好ましくは１００ｍｍ以下であり、さらに好ましくは８５ｍｍ以下である。
【００２９】
（ピリング性）
得られた不織布をＪＩＳ Ｌ１０７６（織物及び編物のピリング試験方法）のＣ法（アピアランス・リテンション形試験機を用いる方法）に準じて試験した。試料ホルダの底面積は約２６ｃｍ2、押圧荷重は約６．４０Ｎ（６５０ｇｆ）で１００回転した後、ピリング判定標準写真４の評価基準であるＨ号、Ｍ号、Ｌ号、Ｎ号を準用してピリング性を評価した。但し、織物及び編物におけるＨ号の状態は、本発明のような開孔不織布に関しては得られず、かわりに毛羽が抜けて毛羽同士が中央で絡まった状態が得られるので、この状態をＨ’号として本発明の評価基準に用いた。すなわち本発明では、Ｈ’級（ピリング性劣る）、Ｍ級（ピリング性やや劣る）、Ｌ級（ピリング性優れる）、Ｎ級（ピリング性特に優れる）の４段階評価とした。
【００３０】
（引張強さ及び伸び率）
得られた不織布より２５ＯｍｍＸ５０ｍｍの試験片をタテ方向及びヨコ方向にそれぞれ３枚採取し、ＪＩＳ Ｌ１０９６（一般織物試験方法）の６．１２．１ Ａ法（ストリップ法）に準じて引張強さ及び伸び率の測定を行った。試験機には、定速引張試験機（テンシロンＵＣＴ−５００、オリエンテックコーポレーション製）を用いて、巾５０ｍｍ、つかみ間隔２００ｍｍ、引張速度２００ｍｍ／分で伸長させ、試料が破断するまでに最も大きい荷重とその時の伸び率を測定し、タテ方向及びヨコ方向について、それぞれの平均値を求め、引張強さ及び伸び率とした。
【００３１】
【実施例】
（実施例１）
乾式法のウエブ形成装置により、繊度２．２デシテックス、繊維長４４ｍｍのポリプロピレン／低融点ポリプロピレンサイドバイサイド型の接着性繊維である潜在捲縮性複合繊維２０％と繊度１．７デシテックス、繊維長３８ｍｍのレーヨン繊維８０％からなる重量３０ｇ／ｍ2のクロスレイされた繊維ウエブＡを作成した。次に、繊度２．２デシテックス、繊維長４４ｍｍのポリプロピレン／低融点ポリプロピレンサイドバイサイド型の接着性繊維である潜在捲縮性複合繊維５％と繊度１．７デシテックス、繊維長３８ｍｍのレーヨン繊維９５％からなる重量３０ｇ／ｍ2のクロスレイされた繊維ウエブＢを作成して、繊維ウエブＡの上に積層した。この積層した繊維ウエブを８０メッシュ平織り金網のコンベアーベルトからなる開孔のある支持体上に載置して、繊維ウエブの上部より、水圧４ＭＰａの高圧水を、直径０．１３ｍｍのノズル孔が０．６ｍｍ間隔で直線状に配列されたノズルプレート１本より噴射させ、高速水流となし、繊維ウエブにあて、繊維ウエブに第一回目の予備的絡合処理を行った。次に、この予備処理された繊維ウエブを反転させて、第一回目と同じ開孔のある支持体上に載置して、第一回目の予備処理と同じ方法で第二回目の予備的絡合処理を行った。次に、繊維ウエブＡが開孔形成用支持体と接触するように、この予備処理された繊維ウエブを再び反転させて１０メッシュ平織り横ナックルタイプの、プラスチックのコンベアーベルトからなる開孔形成用支持体上に載置して、繊維ウエブの上部より、水圧８ＭＰａの高圧水を、直径０．１３ｍｍのノズル孔が０．６ｍｍ間隔で直線状に配列されたノズルプレート２本より噴射させ、高速水流となし、繊維ウエブにあて、繊維ウエブを絡合処理すると同時に開孔処理した。次に、この開孔及び、絡合処理した繊維ウエブを平織り金網からなるコンベアーベルトの上に載置して、エアースルー型のドライヤーの中で、潜在捲縮性複合繊維の接着成分である低融点ポリプロピレン樹脂が溶融するように、１５５°Ｃの温度で、潜在捲縮発現処理と熱接着処理を行い開孔不織布を得た。この開孔不織布の重量は５９．７ｇ／ｍ2であり、厚さは０．８６ｍｍ、破断時の引張強さは、タテ方向が８０．２Ｎ／５０ｍｍ巾、ヨコ方向が３１．６Ｎ／５０ｍｍ巾、破断時の伸び率は、タテ方向が３０．８％、ヨコ方向が５３．０％、カンチレバー法による剛軟度は６８ｍｍ、ピリングテストによる耐摩耗性の度合いは、表（ウエブＡ側の面であり、接着性繊維の混合比率の多い面）がＬ級、裏（ウエブＢ側の面であり、接着性繊維の混合比率の少ない面）がＬ級であった。
【００３２】
（実施例２）
実施例１の繊度２．２デシテックス、繊維長４４ｍｍのポリプロピレン／低融点ポリプロピレンサイドバイサイド型の接着性繊維である潜在捲縮性複合繊維のかわりに、繊度１．７デシテックス、繊維長５１ｍｍのポリプロピレン／ポリエチレンサイドバイサイド型接着性複合繊維を用いて、接着性複合繊維の接着成分であるポリエチレン樹脂が溶融するように、１４０°Ｃの温度で、熱接着処理を行ったこと以外は実施例１と同様にして、開孔不織布を得た。この開孔不織布の重量は５９．３ｇ／ｍ2であり、厚さは０．８７ｍｍ、破断時の引張り強さは、タテ方向が７４．９Ｎ／５０ｍｍ巾、ヨコ方向が２９．７Ｎ／５０ｍｍ巾、破断時の伸び率は、タテ方向が３０．３％、ヨコ方向が６２．３％、カンチレバー法による剛軟度は７７ｍｍ、ピリングテストによる耐摩耗性の度合いは、表（ウエブＡ側の面であり、接着性繊維の混合比率の多い面）がＬ級、裏（ウエブＢ側の面であり、接着性繊維の混合比率の少ない面）がＬ級であった。
【００３３】
（実施例３）
実施例１の繊維ウエブＡのかわりに、繊度２．２デシテックス、繊維長４４ｍｍのポリプロピレン／低融点ポリプロピレンサイドバイサイド型の接着性繊維である潜在捲縮性複合繊維３０％と繊度１．７デシテックス、繊維長３８ｍｍのレーヨン繊維７０％からなる重量３０ｇ／ｍ2のクロスレイされた繊維ウエブＡを作成したこと以外は実施例１と同様にして、開孔不織布を得た。この開孔不織布の重量は６０．１ｇ／ｍ2であり、厚さは０．８６ｍｍ、破断時の引張り強さは、タテ方向が９４．４Ｎ／５０ｍｍ巾、ヨコ方向が３７．４Ｎ／５０ｍｍ巾、破断時の伸び率は、タテ方向が４１．５％、ヨコ方向が５９．８％、カンチレバー法による剛軟度は７７ｍｍ、ピリングテストによる耐摩耗性の度合いは、表（ウエブＡ側の面であり、接着性繊維の混合比率の多い面）がＮ級、裏（ウエブＢ側の面であり、接着性繊維の混合比率の少ない面）がＬ級であった。
【００３４】
上記の実施例１〜３の結果を表１にまとめた。これらの結果から明らかなように、本発明の開孔不織布は剛軟度の値が小さく風合いが柔軟であり、しかも両面ともにピリング性がＬ級以上で耐摩耗性に優れ、さらに両面同等に耐摩耗性に優れているため、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに好適である。
【００３５】
（比較例１）
実施例１の繊維ウエブＡのかわりに、繊度２．２デシテックス、繊維長４４ｍｍのポリプロピレン／低融点ポリプロピレンサイドバイサイド型の接着性繊維である潜在捲縮性複合繊維５％と繊度１．７デシテックス、繊維長３８ｍｍのレーヨン繊維９５％からなる重量３０ｇ／ｍ2のクロスレイされた繊維ウエブＡを作成したこと以外は実施例１と同様にして、開孔不織布を得た。この開孔不織布の重量は５６．０ｇ／ｍ2であり、厚さは０．８５ｍｍ、破断時の引張り強さは、タテ方向が７４．４Ｎ／５０ｍｍ巾、ヨコ方向が２８．９Ｎ／５０ｍｍ巾、破断時の伸び率は、タテ方向が３０．８％、ヨコ方向が６０．８％、カンチレバー法による剛軟度は４３ｍｍ、ピリングテストによる耐摩耗性の度合いは、表（ウエブＡ側の面）がＨ’級、裏（ウエブＢ側の面）がＬ級であった。このように、繊維構造物全体に占める接着性繊維の重量比率が少なく、しかも表面層と裏面層の接着性繊維の重量比率の差が５％未満である比較例１の開孔不織布は、表面の耐摩耗性が劣り、本発明が目的とする用途には使用できないものであった。
【００３６】
（比較例２）
実施例１の繊維ウエブＡのかわりに、繊度２．２デシテックス、繊維長４４ｍｍのポリプロピレン／低融点ポリプロピレンサイドバイサイド型の接着性繊維である潜在捲縮性複合繊維４０％と繊度１．７デシテックス、繊維長３８ｍｍのレーヨン繊維６０％からなる重量３０ｇ／ｍ2のクロスレイされた繊維ウエブＡを作成したこと、及び繊維ウエブＢのかわりに、繊度２．２デシテックス、繊維長４４ｍｍのポリプロピレン／低融点ポリプロピレンサイドバイサイド型の接着性繊維である潜在捲縮性複合繊維４０％と繊度１．７デシテックス、繊維長３８ｍｍのレーヨン繊維６０％からなる重量３０ｇ／ｍ2のクロスレイされた繊維ウエブＢを作成したこと以外は実施例１と同様にして、開孔不織布を得た。この開孔不織布の重量は５８．１ｇ／ｍ2であり、厚さは０．９０ｍｍ、破断時の引張り強さは、タテ方向が１０５．３Ｎ／５０ｍｍ巾、ヨコ方向が３９．２Ｎ／５０ｍｍ巾、破断時の伸び率は、タテ方向が４２．０％、ヨコ方向が７１．３％、カンチレバー法による剛軟度は１２４ｍｍ、ピリングテストによる耐摩耗性の度合いは、表（ウエブＡ側の面）がＮ級、裏（ウエブＢ側の面）がＮ級であった。このように、繊維構造物全体に占める接着性繊維の重量比率が３０重量％を超え、しかも表面層と裏面層の接着性繊維の重量比率の差が５％未満である比較例２の開孔不織布は、両面の耐摩耗性は優れるものの、剛軟度の値が高く柔軟性に劣るため、本発明が目的とする用途には使用できないものであった。
【００３７】
（比較例３）
実施例２の繊維ウエブＡのかわりに、繊度１．７デシテックス、繊維長５１ｍｍのポリプロピレン／ポリエチレンサイドバイサイド型接着性複合繊維５％と繊度１．７デシテックス、繊維長３８ｍｍのレーヨン繊維９５％からなる重量３０ｇ／ｍ2のクロスレイされた繊維ウエブＡを作成したこと以外は実施例２と同様にして、開孔不織布を得た。この開孔不織布の重量は６０．３ｇ／ｍ2であり、厚さは０．９３ｍｍ、破断時の引張り強さは、タテ方向が６９．３Ｎ／５０ｍｍ巾、ヨコ方向が２９．５Ｎ／５０ｍｍ巾、破断時の伸び率は、タテ方向が２６．３％、ヨコ方向が５７．３％、カンチレバー法による剛軟度は６１ｍｍ、ピリングテストによる耐摩耗性の度合いは、表（ウエブＡ側の面）がＨ’級、裏（ウエブＢ側の面）がＬ級であった。このように、繊維構造物全体に占める接着性繊維の重量比率が少なく、しかも表面層と裏面層の接着性繊維の重量比率の差が５％未満である比較例３の開孔不織布は、表面の耐摩耗性が劣り、本発明が目的とする用途には使用できないものであった。
【００３８】
表１．開孔不織布の評価（実施例１〜３）
表２．開孔不織布の評価（比較例１〜３）
【発明の効果】
本発明は、接着性繊維５〜３０重量％と該接着性繊維以外の繊維７０〜９５重量％からなり、繊維が３次元的に絡合された開孔不織布であって、該開孔不織布の表面層と裏面層において該接着性繊維の重量比率が５％以上異なり、かつ該表面層と該裏面層において該接着性繊維が繊維接着していることを特徴とする開孔不織布であり、絡合と開孔による柔軟性保持効果と繊維接着処理による耐摩耗性の向上効果に加えて、接着点を多く持つ層を片面に偏在させることによって、偏在させない場合の耐摩耗性と同等の耐摩耗性を両面ともに保ちながら、風合いをさらに柔軟にする効果を得ることができるため、ふき取り布、おむつ部材、壁装材、内装材、ガーゼ、水切りシート及び袋、排水溝ゴミ取りシート、簡易液体フィルター、マスク内ろ材などに好適な開孔不織布を提供することができる。また、本発明の開孔不織布をふき取り布に用いると、開孔部分にゴミを補足することができ、また開孔不織布とふき取りされる面との間の接触面積が少なくなるので、摩擦による抵抗が少なくふき取り易い。このため本発明の開孔不織布は特にふき取り布に好適である。[0001]
BACKGROUND OF THE INVENTION
The present invention provides a wipe cloth, a diaper member, a wall covering material, an interior material, a gauze, a draining sheet and a bag, a drainage dust removing sheet, a simple liquid filter, a mask having both excellent flexibility and excellent wear resistance. The present invention relates to a perforated nonwoven fabric that is used as an inner filter material and is particularly suitable for a wipe, and a manufacturing method thereof.
[0002]
[Prior art]
Various non-woven fabrics in which fibers are entangled by hydroentanglement and fiber intersections are bonded by heat-bonding fibers have been proposed as flexible non-woven fabrics. For example, in Japanese Patent Application Laid-Open No. 10-237751, a web composed of 20-50% latent crimpable conjugate fiber and 80-50% non-thermally bonded fiber is entangled with the fiber by hydroentanglement, and subjected to heat treatment, There has been proposed a non-woven fabric excellent in flexibility and tactile sensation in which the crimp of the latent crimped composite fiber is expressed and the low melting point component is thermally bonded. However, since this non-woven fabric is not perforated, it was inferior in wiping property, air permeability and water permeability. Japanese Patent Laid-Open No. 9-302562 discloses a perforated nonwoven fabric in which a nonwoven fabric in which fibers are entangled by the action of a high-pressure fluid flow and fibers are rearranged to form apertures is elongated in the lateral direction. And the open nonwoven fabric in which a part of thermoplastic fiber is heat-sealed is proposed. However, such nonwoven fabrics show improved drape and lateral strength, but when the proportion of thermoplastic fibers that have been heat-sealed is small, there are many fibers coming out and inferior in wear resistance. When the ratio of the thermoplastic fiber was large, the texture was hard and the flexibility was poor. Further, when producing the apertured nonwoven fabric, when the apertured nonwoven fabric is peeled off from the aperture forming support, fibers partially entangled with the aperture forming support are pulled and contacted with the aperture forming support. There was a problem that fluff would occur on the surface. And when such an apertured non-woven fabric is used for wipe cloth, diaper members, wall covering materials, interior materials, gauze, draining sheets and bags, drainage gutter removal sheets, simple liquid filters, mask filter media, etc. There was a problem that the surface was inferior in wear resistance. Further, in order to stop the generated fluff, there is a problem that if the ratio of the adhesive fibers of the entire open nonwoven fabric is increased, the texture becomes hard and the flexibility is inferior.
[0003]
[Problems to be solved by the invention]
The present invention has been made to solve the above-described problems, and has both excellent flexibility and excellent wear resistance, which are contradictory properties, and is excellent in wear resistance on both sides. Also used for wipe cloth, diaper members, wall covering materials, interior materials, gauze, draining sheets and bags, drainage gutter removal sheets, simple liquid filters, mask filter media, etc. It is an object to provide a manufacturing method thereof.
[0004]
[Means for Solving the Problems]
The invention of claim 1 is an open nonwoven fabric comprising 5 to 30% by weight of adhesive fibers and 70 to 95% by weight of fibers other than the adhesive fibers, wherein the fibers are entangled three-dimensionally. An apertured nonwoven fabric characterized in that the weight ratio of the adhesive fibers is different by 5% or more between the surface layer and the back surface layer of the porous nonwoven fabric, and the adhesive fibers are fiber-bonded in the surface layer and the back surface layer. is there. That is, in the present invention, since the fibers are entangled three-dimensionally, the texture is flexible and the fiber structure has practical strength as a wiping cloth. Since it is bonded, it is a fiber structure with abrasion resistance. In addition, since the adhesive fiber is 5 to 30% by weight of the entire fiber structure, the texture of the adhesive fiber due to thermal bonding is not greatly changed, and a flexible texture suitable for practical use can be maintained. In addition, the fiber structure has an opening that penetrates from the front surface to the back surface by changing the fiber orientation by the action of water flow, etc., so that it has a structure excellent in wiping property, air permeability, and water permeability. ing. Furthermore, in the present invention, when the fibers are entangled three-dimensionally by the action of water flow, a layer (surface) belonging to the surface side where the fluff is large in the fiber structure, that is, the surface side in contact with the hole forming support. Since the weight ratio of the adhesive fibers contained in the layer or the back surface layer is 5% or more than the weight ratio of the adhesive fibers contained in the layer belonging to the opposite face (the back layer or the surface layer), hole formation Fluffing on the surface with many fuzz, which is the surface in contact with the support, is improved in wear resistance, and can exhibit the same wear resistance as other surfaces. Further, when attention is paid to one fiber in the fiber structure, since the fiber is entangled three-dimensionally, both the front surface layer and the back surface layer have entanglement points with other fibers. And, in the layer belonging to the surface side where the fluff is large, the adhesion is sufficiently performed at the entanglement point with the adhesive fiber, so that the fiber is hardly detached. As a result, the fiber structure is less likely to lose fiber even on the surface opposite to the surface with many fluffs, and can exhibit good wear resistance. In addition, since the weight ratio of the adhesive fibers contained in the layer belonging to the surface opposite to the surface with many fuzz is 5% or more lower than the layer belonging to the surface belonging to many fuzz, the opposite surface also has the same weight ratio of the adhesive fibers. Compared with, the adhesion point of the said whole fiber structure decreases, and the said fiber structure becomes a softer texture. As described above, in the present invention, by distributing the layer having many adhesion points on one side, it is possible to further soften the texture while maintaining both sides of the wear resistance equivalent to the wear resistance when not unevenly distributed. Therefore, it is possible to provide an apertured nonwoven fabric suitable for wiping cloths, diaper members, wall covering materials, interior materials, gauze, draining sheets and bags, drainage groove dust removal sheets, simple liquid filters, mask filter media and the like. In addition, when the apertured nonwoven fabric of the present invention is used for a wipe, it is possible to catch dust in the aperture portion, and the contact area between the apertured nonwoven fabric and the surface to be wiped is reduced, so that resistance due to friction is reduced. There is little and is easy to wipe off. For this reason, the apertured nonwoven fabric of the present invention is particularly suitable for wipes.
[0005]
The invention according to claim 2 is the perforated nonwoven fabric according to claim 1, characterized in that the adhesive fiber is 5 to 20% by weight and the fiber other than the adhesive fiber is 80 to 95% by weight. In the apertured nonwoven fabric according to Item 1, an apertured nonwoven fabric having particularly excellent flexibility can be obtained by adjusting the adhesive fiber to 5 to 20% by weight.
[0006]
The invention according to claim 3 is the open nonwoven fabric according to claim 1 or 2, wherein the adhesive fiber is a latent crimpable fiber. That is, in the open nonwoven fabric according to claim 1 or 2, in the core-sheath type composite fiber, for example, the sheath part is a polymer having a melting point lower than that of the core part, and not only crimps are expressed by heat treatment. By using a fiber in which the sheath part is bonded to other fibers, the open nonwoven fabric according to claim 1 or 2 can be obtained by the action as an adhesive fiber, and fuzz prevention can be achieved by expression of crimp. Since it is effective, it is possible to obtain an open nonwoven fabric with particularly little fluff.
[0007]
The invention according to claim 4 is the apertured nonwoven fabric according to any one of claims 1 to 3, characterized in that it contains 30% by weight or more of hydrophilic fibers. By including 30% by weight or more of hydrophilic fibers in the porous non-woven fabric, wipe cloth, diaper members, wall covering materials, interior materials, gauze, draining sheets and bags, drainage dust removal sheets, simple liquid filters, mask filter media, etc. Among these applications, an apertured nonwoven fabric that is particularly suitable when hydrophilicity is required can be obtained.
[0008]
Invention of Claim 5 is an apertured nonwoven fabric in any one of Claims 1-4 whose entanglement is based on a hydroentanglement method, In the apertured nonwoven fabric in any one of Claims 1-4, By forming the entanglement by the hydroentanglement method, an opening can be formed simultaneously with the entanglement, and an open nonwoven fabric having a low weight that cannot be obtained by the needle punch method can be obtained.
[0009]
The invention of claim 6 is to form a fiber web A composed of an adhesive fiber and a fiber other than the adhesive fiber, and a fiber web B in which the weight ratio of the adhesive fiber is 5% or less less than the fiber web A. After forming so that the adhesive fiber is 5 to 30 wt% and the fibers other than the adhesive fiber are 70 to 95 wt% with respect to the total fibers contained in the fiber web A and the fiber web B, After the fiber web is laminated and placed on the opening forming support so that the fiber web A is the lowermost layer and the fiber web B is the uppermost layer, the fiber web is laminated on the laminated fiber web by water flow treatment. This is a method for producing an apertured nonwoven fabric in which the adhesive fibers are subjected to fiber bonding treatment after being entangled and opened. Abrasion resistance of open nonwoven fabric is prevented It is possible to above. Further, the fluff generated from the fiber web A generated when peeling from the opening forming support can be sufficiently suppressed since the blending ratio of the adhesive fibers in the fiber web A is large. In addition, since the adhesive fiber is increased only on one side, the entire open nonwoven fabric is not hardened. In this way, by unevenly distributing a layer having many adhesion points on one side, the effect of making the texture more flexible than when not unevenly distributed is obtained while maintaining both sides of the wear resistance equivalent to the wear resistance when not unevenly distributed. Therefore, it is possible to provide a perforated nonwoven fabric suitable for wipe cloth, diaper members, wall covering materials, interior materials, gauze, draining sheets and bags, drainage trash removal sheets, simple liquid filters, mask filter media, etc. it can. In addition, when the apertured nonwoven fabric of the present invention is used for a wipe, it is possible to catch dust in the aperture portion, and the contact area between the apertured nonwoven fabric and the surface to be wiped is reduced, so that resistance due to friction is reduced. There is little and is easy to wipe off. For this reason, the apertured nonwoven fabric of the present invention is particularly suitable for wipes.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
The present invention is an apertured nonwoven fabric comprising 5 to 30% by weight of adhesive fibers and 70 to 95% by weight of fibers other than the adhesive fibers, wherein the fibers are three-dimensionally entangled, The open nonwoven fabric is characterized in that the weight ratio of the adhesive fibers is different by 5% or more between the front surface layer and the back surface layer, and the adhesive fibers are fiber-bonded in the front surface layer and the back surface layer.
[0011]
The present invention also provides a fiber web A when forming a fiber web A composed of an adhesive fiber and a fiber other than the adhesive fiber, and a fiber web B in which the weight ratio of the adhesive fiber is 5% or less than that of the fiber web A. The fiber web is formed so that the adhesive fiber is 5 to 30% by weight and the fibers other than the adhesive fiber are 70 to 95% by weight with respect to the total fibers contained in A and the fiber web B. After the fiber web is laminated and placed on the support for opening formation so that A is the lowermost layer and fiber web B is the uppermost layer, the fiber web laminated by water flow treatment is entangled with the laminated fiber web And after making it open, it is a manufacturing method of the open nonwoven fabric which performs the fiber-bonding process of this adhesive fiber.
[0012]
The adhesive fiber used in the present invention is a fiber that melts at a melting point that is preferably 10 ° C. or more lower than fibers other than the adhesive fiber, and is preferably a synthetic fiber made of one kind of thermoplastic resin or a melting point. Is a composite fiber in which two or more types of resins differing by 10 ° C. or more are combined, and a composite fiber having a resin that melts at a lower melting point than fibers other than the adhesive fiber on the surface of the fiber is preferable. A fiber in which at least a part of the adhesive fiber melts at 80 ° C. or higher, preferably 100 ° C. or higher when the adhesive fiber is heated is suitable. Examples of the synthetic fiber made of one kind of thermoplastic resin include synthetic fibers made of a thermoplastic resin such as polyolefin fiber, polyester fiber, polyamide fiber, and acrylic fiber. Examples of composite fibers in which two or more kinds of resins having different melting points are combined include, for example, resins such as copolymer polyester / polyester, copolymer polypropylene / polypropylene, polypropylene / polyamide, polyethylene / polypropylene, polypropylene / polyester, and polyethylene / polyester. There is a composite fiber made of a combination of
[0013]
Moreover, it is more preferable that the adhesive fiber used in the present invention is the above-mentioned conjugate fiber and a latent crimpable fiber. As the composite fiber having such latent crimpability, for example, a fiber having a composite structure such as a core-sheath type or a side-by-side type composed of a plurality of resin components having different temperature characteristics, one component in the resin component and another component The heat shrinkage rate and the melting temperature are different from each other, and one resin component softens and shrinks, and heat treatment is performed at a temperature at which the other resin components do not substantially shrink. These are composite fibers in which individual fibers have coiled (or spiral) crimps. Furthermore, this composite fiber can be used as an adhesive fiber if heat treatment is performed up to the melting temperature of one component in the resin component. The composite fiber which can also be used can be mentioned. In such a composite fiber, when the optimal crimp expression conditions are selected, the number of crimps after expression increases to at least twice the number of crimps at room temperature before expression in the state where no external force is applied. Desirably, for example, the number of crimps of 10 to 20 pieces / inch at room temperature increases to about 40 to 200 pieces / inch when heated at 110 to 170 ° C. for 15 minutes in a state where no external force is applied by the fiber alone. preferable.
[0014]
Examples of the composite fiber having both adhesiveness and latent crimpability include resins such as copolymer polyester / polyester, copolymer polypropylene / polypropylene, polypropylene / polyamide, polyethylene / polypropylene, polypropylene / polyester, and polyethylene / polyester. There is a composite fiber made of a combination. When such a composite fiber is heat-treated to express crimps, the function as an adhesive fiber can provide an apertured nonwoven fabric according to the present invention, and the effect of preventing fuzz due to crimping occurs. In particular, an open nonwoven fabric with less fuzz can be obtained.
[0015]
The fibers other than the adhesive fibers used in the present invention are composed of a resin or a component that melts at a melting point that is higher by 10 ° C. or more than the melting point of the resin that constitutes the adhesive component of the resin that constitutes the adhesive fiber. It is a fiber and can be appropriately selected regardless of the type of fiber such as synthetic fiber, semi-synthetic fiber and natural fiber. In the case of synthetic fibers, such fibers other than adhesive fibers may be selected as appropriate, whether they are synthetic fibers made of one kind of thermoplastic resin or composite fibers in which two or more different kinds of resins are combined. Can be used.
[0016]
The hydrophilic fiber used in the present invention is preferably a fiber having good wettability to water, particularly preferably one having excellent water absorption, and is appropriately selected regardless of the type of fiber such as synthetic fiber, semi-synthetic fiber or natural fiber. it can. Examples of such hydrophilic fibers include rayon fibers, cotton fibers, acetate fibers, and acrylic fibers. In the present invention, by including 30% by weight or more of such a hydrophilic fiber, a wiped cloth, a diaper member, a gauze, a draining sheet and a bag, a drainage channel dust collecting sheet, a simple liquid filter, which are particularly required to be hydrophilic, A perforated nonwoven fabric suitable for a filter medium in a mask can be obtained.
[0017]
In the apertured nonwoven fabric of the present invention, it is necessary to comprise 5 to 30% by weight of adhesive fibers and 70 to 95% by weight of fibers other than the adhesive fibers, but 5 to 20% by weight of adhesive fibers and other than the adhesive fibers. When the fiber is 80 to 95% by weight, both flexibility and wear resistance are excellent, which is preferable. When the adhesive fiber is less than 5% by weight, the practical strength is insufficient, the fluff is insufficient, and the open nonwoven fabric with wear resistance cannot be obtained. On the other hand, if the adhesive fiber exceeds 30% by weight, the texture becomes hard and the flexibility requirement in each application targeted by the present invention cannot be satisfied.
[0018]
The perforated nonwoven fabric of the present invention preferably contains 30% by weight or more of hydrophilic fibers, and particularly requires hydrophilic properties, such as wipes, diapers, gauze, draining sheets and bags, drainage dust removal sheets, and simple liquids. A perforated nonwoven fabric suitable for a filter, a filter medium in a mask and the like can be obtained.
[0019]
In the open nonwoven fabric of the present invention, the weight ratio of the adhesive fibers needs to be different by 5% or more between the front surface layer and the back surface layer. That is, the weight ratio of the adhesive fibers contained in the layer (surface layer or back surface layer) belonging to the surface side in contact with the hole forming support is the adhesive fiber contained in the layer (back surface layer or surface layer) belonging to the opposite surface. When the weight ratio is 5% or more than the weight ratio, fluffing on the surface where the fuzzy surface, which is in contact with the hole forming support, is prevented and wear resistance is improved. Abrasion can be shown. If the difference in weight ratio is less than 5% and the wear resistance is to be equalized on both sides, the weight ratio of the adhesive fibers contained in the perforated nonwoven fabric will increase more than necessary, and the texture will become harder. The flexibility requirement in each application targeted by the present invention cannot be satisfied.
[0020]
In the present invention, as a method of laminating the fiber layers, the fiber layers can be laminated by any known fiber web forming method such as a dry method, a wet method, a melt spinning method or the like, or a combination of these methods. When the fiber web is laminated, the fiber web consisting of 5% by weight or more of adhesive fibers is referred to as fiber web A, and the fiber web is made of 5% by weight or more of adhesive fibers, and the weight of adhesive fibers is higher than that of fiber web A. When the fiber web B is a fiber web having a ratio of 5% or less, the adhesive fiber is 5 to 30% by weight and the fibers other than the adhesive fiber with respect to the total fibers contained in the fiber web A and the fiber web B. A method of laminating the fiber web is desirable so that the amount of the fiber becomes 70 to 95% by weight. The fiber web A is preferably composed of 20 to 30% by weight of adhesive fibers and 80 to 70% by weight of fibers other than the adhesive fibers, and the fiber web B is bonded to 5 to 15% by weight of adhesive fibers. It is preferable to comprise 95 to 85% by weight of fibers other than the conductive fibers.
[0021]
In the present invention, the method of performing the entanglement treatment and the hole opening treatment on the laminated fiber layers is carried out by the method of simultaneously performing the entanglement and the hole opening by the fluid flow in the water flow entanglement method, the needle punch method or the like. Thereafter, for example, there is a method of opening holes while changing the orientation of the fiber through a fiber layer entangled between a pointed roll and a brush roll, and a hydroentanglement method capable of high-speed production is suitable.
[0022]
In the case of the hydroentanglement method, the fiber layer laminated so that the fiber web A is the lowermost layer and the fiber web B is the uppermost layer is placed on the opening forming support. As the support for forming the hole, a conveyor belt made of a metal or plastic net, a water permeable drum around which the net is wound, or a water permeable drum with a hole made of metal or plastic is used. Can be used. In the case of nets, nets of various woven structures such as plain weave and twill weave can be used, and a woven structure of 5 to 60 mesh is suitable, but 5 to 30 mesh is particularly suitable for obtaining a soft texture. Yes. If a woven structure exceeding 60 mesh is used, it is difficult to form a non-woven fabric with holes. When a perforated drum is used, a perforated drum having a perforated area ratio of 10 to 80% is suitable.
[0023]
Next, a high-speed water stream is jetted from the upper part of the fiber layer placed on the hole-forming support to entangle the fiber layer and form a fiber structure having holes. For the generation of high-speed water flow, high-pressure water with a water pressure of 3 to 20 MPa is sprayed from one or a plurality of nozzle plates in which nozzle holes with a diameter of 0.1 to 0.3 mm are arranged at intervals of 0.3 to 3 mm, A high-speed water flow method is suitable.
[0024]
In the hole opening treatment by the water flow entanglement method, the fiber layer is placed on a support having a hole different from the hole forming support, and preliminarily entangled with a high-speed water flow. After performing the joint treatment, the hole opening treatment by the water flow entanglement may be performed. As the support having an opening used for the preliminary treatment, a support having an arbitrary opening may be selected and used regardless of the mesh of the opening forming support or the value of the opening area ratio. it can. Moreover, in this preliminary entanglement treatment, the fiber web A can be either the uppermost layer or the lowermost layer when the fiber layer is placed on a support having a hole. It is. However, in this preliminary entanglement process, it is desirable that the pressure before jetting the high-speed water flow is lower than the pressure when forming the holes after the preliminary process, and the number of nozzle plates used is reduced. desirable.
[0025]
In this invention, after performing an entangling process and an opening process to a fiber layer, the fiber bonding process by the adhesive fiber contained in the formed fiber structure is performed. The fiber bonding treatment can be performed by placing a fiber structure on a substantially uneven conveyor and blowing hot air, or by placing hot air on a conveyor or drum-like support that is substantially uneven. It is desirable to carry out by a method of passing a structure and its support, a method of placing a fiber structure on a heated drum-shaped support, or the like.
[0026]
As for the opening of the open nonwoven fabric thus formed, the area of the portion penetrating from the surface to the back surface of the fiber structure is preferably 10 to 80% of the entire surface, and 10 to 50 % Is optimal. If it is less than 10%, the texture is hard, and if it exceeds 80%, form stability is lost, which is not preferable.
[0027]
The open nonwoven fabric formed as described above has a layer having many adhesion points unevenly distributed on one side in addition to the effect of maintaining flexibility by entanglement and opening and the effect of improving abrasion resistance by fiber bonding treatment. With this, it is possible to obtain the effect of further softening the texture while maintaining both the wear resistance equivalent to the wear resistance when not unevenly distributed, so that the wipe cloth, diaper member, wall covering material, interior material, gauze, It is possible to provide an apertured non-woven fabric suitable for draining sheets and bags, drainage groove dust removal sheets, simple liquid filters, mask filter media and the like. In addition, when the apertured nonwoven fabric of the present invention is used for a wipe, it is possible to catch dust in the aperture portion, and the contact area between the apertured nonwoven fabric and the surface to be wiped is reduced, so that resistance due to friction is reduced. There is little and is easy to wipe off. For this reason, the apertured nonwoven fabric of the present invention is particularly suitable for wipes.
[0028]
Next, the present invention will be described in detail with reference to examples and comparative examples. However, the examples illustrate specific conditions to the extent that the present invention can be understood. It is not limited to. In addition, the following test method was used for evaluation regarding the softness | flexibility, abrasion resistance, tensile strength, and tensile elongation of an Example and a comparative example.
(Flexibility)
From the obtained nonwoven fabric, three test pieces of 20 mm × 200 mm were sampled in the vertical direction and the horizontal direction, respectively, and the bending resistance was determined according to the 6.19.1A method (45 ° cantilever method) of JIS L1096 (general fabric test method). The average values of the measured values in the vertical direction and the horizontal direction were obtained, and these average values were further averaged to obtain the bending resistance. The bending resistance required for the intended use of the apertured nonwoven fabric of the present invention is preferably 100 mm or less, more preferably 85 mm or less.
[0029]
(Pilling)
The obtained non-woven fabric was tested in accordance with JIS L1076 (method for woven and knitted fabric pilling test) C method (method using appearance and retention type tester). The bottom area of the sample holder is about 26cm 2 Then, after rotating 100 times at a pressing load of about 6.40 N (650 gf), the pilling property was evaluated by applying the evaluation standards of the pilling determination standard photograph 4 as Nos. H, M, L, and N. However, the state of No. H in the woven fabric and the knitted fabric is not obtained with respect to the apertured nonwoven fabric as in the present invention, and instead, a state in which the fluff comes out and the fluff is entangled in the center is obtained. It was used as an evaluation standard for the present invention as a number. That is, in this invention, it was set as four-step evaluation of H 'class (poor pilling property), M class (slightly inferior pilling property), L class (excellent pilling property), and N class (particularly excellent pilling property).
[0030]
(Tensile strength and elongation)
Three test pieces of 25Omm × 50mm were collected from the obtained nonwoven fabric in the vertical and horizontal directions, respectively, and the tensile strength and elongation were in accordance with 6.12.1 A method (strip method) of JIS L1096 (general fabric test method). The rate was measured. Using a constant speed tensile tester (Tensilon UCT-500, manufactured by Orientec Corporation), the tester is extended at a width of 50 mm, a gripping interval of 200 mm, and a tensile speed of 200 mm / min. And the elongation at that time was measured, the average value was calculated | required about the vertical direction and the horizontal direction, and it was set as tensile strength and elongation rate.
[0031]
【Example】
Example 1
With a dry-type web forming device, a polypropylene / low melting point polypropylene side-by-side adhesive fiber having a fineness of 2.2 dtex and a fiber length of 44 mm, a latent crimpable composite fiber of 20%, a fineness of 1.7 dtex and a fiber length of 38 mm Weight 30g / m consisting of 80% rayon fiber 2 A cross-laid fiber web A was prepared. Next, from 5% latent crimpable composite fiber, a polypropylene / low melting point polypropylene side-by-side adhesive fiber with a fineness of 2.2 dtex and a fiber length of 44 mm, and 95% rayon fiber with a fineness of 1.7 dtex and a fiber length of 38 mm Weight of 30g / m 2 A cross-laid fiber web B was prepared and laminated on the fiber web A. This laminated fiber web is placed on a support having an opening made of a conveyor belt of 80 mesh plain weave wire mesh, and high pressure water with a water pressure of 4 MPa is provided from the top of the fiber web, and a nozzle hole with a diameter of 0.13 mm is 0. The nozzle plate was sprayed from one nozzle plate arranged in a straight line at intervals of 6 mm, formed into a high-speed water flow, applied to the fiber web, and subjected to a first preliminary entanglement treatment on the fiber web. Next, the pretreated fiber web is inverted and placed on the support having the same opening as the first time, and the second preliminary entanglement is performed in the same manner as the first time pretreatment. Combined processing was performed. Next, the pre-treated fiber web is inverted again so that the fiber web A is in contact with the hole forming support, and the hole forming support comprising a plastic conveyor belt of a 10 mesh plain weave horizontal knuckle type is provided. Placed on the body, high-pressure water with a water pressure of 8 MPa is jetted from two nozzle plates in which nozzle holes with a diameter of 0.13 mm are linearly arranged at intervals of 0.6 mm from the upper part of the fiber web. The fiber web was entangled with the fiber web and simultaneously subjected to the hole opening treatment. Next, the fiber web subjected to the opening and the entanglement treatment is placed on a conveyor belt made of a plain weave wire mesh, and in the air-through dryer, the adhesive component of the latent crimpable composite fiber is reduced. A latent crimping treatment and a thermal bonding treatment were performed at a temperature of 155 ° C. so that the melting point polypropylene resin was melted to obtain an open nonwoven fabric. The weight of this perforated nonwoven fabric is 59.7 g / m. 2 The thickness is 0.86 mm, the tensile strength at break is 80.2 N / 50 mm wide in the vertical direction, the width is 31.6 N / 50 mm wide, and the elongation at break is 30. 8%, horizontal direction is 53.0%, bending resistance by cantilever method is 68mm, degree of wear resistance by pilling test is the table (surface on the web A side, where the mixing ratio of adhesive fibers is large) Was the L class, and the back (the surface on the web B side, the surface with a low mixing ratio of adhesive fibers) was the L class.
[0032]
(Example 2)
In place of the latent crimpable conjugate fiber which is a polypropylene / low melting point polypropylene side-by-side type adhesive fiber having a fineness of 2.2 dtex and a fiber length of 44 mm in Example 1, a polypropylene / polyethylene having a fineness of 1.7 dtex and a fiber length of 51 mm Using side-by-side type adhesive conjugate fiber, the same procedure as in Example 1 was performed except that the thermal bonding treatment was performed at a temperature of 140 ° C. so that the polyethylene resin as the adhesive component of the adhesive conjugate fiber was melted. A holey nonwoven fabric was obtained. The weight of this perforated nonwoven fabric is 59.3 g / m. 2 The thickness is 0.87 mm, the tensile strength at break is 74.9 N / 50 mm width in the vertical direction, the width is 29.7 N / 50 mm width, and the elongation at break is 30. 5 mm in the vertical direction. 3%, horizontal direction is 62.3%, bending resistance by cantilever method is 77mm, wear resistance degree by pilling test is the table (surface on the web A side, surface with a large mixing ratio of adhesive fibers) Was the L class, and the back (the surface on the web B side, the surface with a low mixing ratio of adhesive fibers) was the L class.
[0033]
Example 3
Instead of the fiber web A of Example 1, 30% latent crimped composite fiber having a fineness of 2.2 dtex and a fiber length of 44 mm, which is a polypropylene / low melting point polypropylene side-by-side adhesive fiber, and a fineness of 1.7 dtex and fiber. Weight 30g / m consisting of 70% rayon fiber with a length of 38mm 2 An apertured nonwoven fabric was obtained in the same manner as in Example 1 except that the cross-laid fiber web A was prepared. The weight of this perforated nonwoven fabric is 60.1 g / m 2 The thickness is 0.86 mm, the tensile strength at break is 94.4 N / 50 mm wide in the vertical direction, the width is 37.4 N / 50 mm wide, and the elongation at break is 41. 5 mm in the vertical direction. 5%, horizontal direction is 59.8%, bending resistance by cantilever method is 77 mm, degree of abrasion resistance by pilling test is a table (surface on the web A side, surface with a large mixing ratio of adhesive fibers) Was the N class, and the back (the surface on the web B side, the surface with a low mixing ratio of adhesive fibers) was the L class.
[0034]
The results of Examples 1 to 3 are summarized in Table 1. As is clear from these results, the apertured nonwoven fabric of the present invention has a low bending resistance value and a soft texture, and also has excellent pilling properties on both sides, excellent wear resistance, and equivalent resistance on both sides. Since it is excellent in abrasion, it is suitable for wipe cloths, diaper members, wall covering materials, interior materials, gauze, draining sheets and bags, drainage gutter removal sheets, simple liquid filters, mask filter media and the like.
[0035]
(Comparative Example 1)
Instead of the fiber web A of Example 1, 5% latent crimpable composite fiber having a fineness of 2.2 dtex and a fiber length of 44 mm, which is a polypropylene / low melting point polypropylene side-by-side adhesive fiber, and a fineness of 1.7 dtex, fiber 30g / m weight consisting of 95% rayon fiber with a length of 38mm 2 An apertured nonwoven fabric was obtained in the same manner as in Example 1 except that the cross-laid fiber web A was prepared. The weight of this perforated nonwoven fabric is 56.0 g / m. 2 The thickness is 0.85 mm, the tensile strength at break is 74.4 N / 50 mm wide in the vertical direction, the width is 28.9 N / 50 mm wide, and the elongation at break is 30. 5 in the vertical direction. 8%, horizontal direction is 60.8%, bending resistance by cantilever method is 43mm, wear resistance degree by pilling test is H 'grade on the front (web A side surface), back (web B side surface) ) Was L class. Thus, the open nonwoven fabric of Comparative Example 1 in which the weight ratio of the adhesive fibers occupying the entire fiber structure is small, and the difference in the weight ratio of the adhesive fibers between the front surface layer and the back surface layer is less than 5%, The wear resistance was inferior and could not be used for the intended purpose of the present invention.
[0036]
(Comparative Example 2)
Instead of the fiber web A of Example 1, 40% latent crimpable composite fiber, which is a polypropylene / low melting point polypropylene side-by-side adhesive fiber having a fineness of 2.2 dtex and a fiber length of 44 mm, and a fineness of 1.7 dtex, fiber 30g / m weight consisting of 60% rayon fiber with a length of 38mm 2 A latently crimped conjugate fiber 40, which is a polypropylene / low melting point polypropylene side-by-side type adhesive fiber having a fineness of 2.2 dtex and a fiber length of 44 mm, instead of the fiber web B. And 30 g / m in weight consisting of 60% rayon fiber with a fineness of 1.7 decitex and a fiber length of 38 mm. 2 A perforated nonwoven fabric was obtained in the same manner as in Example 1 except that the cross-laid fiber web B was prepared. The weight of this perforated nonwoven fabric is 58.1 g / m. 2 The thickness is 0.90 mm, the tensile strength at break is 105.3 N / 50 mm width in the vertical direction, the width is 39.2 N / 50 mm width, and the elongation at break is 42. 2 mm in the vertical direction. 0%, horizontal direction 71.3%, bending resistance by cantilever method is 124mm, degree of wear resistance by pilling test is N class on the front (web A side surface), back (web B side surface) Was N grade. Thus, the opening ratio of Comparative Example 2 in which the weight ratio of the adhesive fibers in the entire fiber structure exceeds 30% by weight and the difference in the weight ratio of the adhesive fibers between the front surface layer and the back surface layer is less than 5%. Although the nonwoven fabric has excellent wear resistance on both sides, it has a high bending resistance and is inferior in flexibility, and therefore cannot be used for the intended purpose of the present invention.
[0037]
(Comparative Example 3)
Weight consisting of 5% polypropylene / polyethylene side-by-side adhesive composite fiber having a fineness of 1.7 decitex and a fiber length of 51 mm, and 95% rayon fiber having a fineness of 1.7 decitex and a fiber length of 38 mm, instead of the fiber web A of Example 2. 30 g / m 2 A perforated nonwoven fabric was obtained in the same manner as in Example 2 except that the cross-laid fiber web A was prepared. The weight of this perforated nonwoven fabric is 60.3 g / m 2 The thickness is 0.93 mm, the tensile strength at break is 69.3 N / 50 mm width in the vertical direction, the width is 29.5 N / 50 mm width, and the elongation at break is 26.5 in the vertical direction. 3%, transverse direction is 57.3%, bending resistance by cantilever method is 61mm, and wear resistance degree by pilling test is H 'class on the front (web A side surface), back (web B side surface) ) Was L class. Thus, the apertured nonwoven fabric of Comparative Example 3 in which the weight ratio of the adhesive fibers occupying the entire fiber structure is small and the difference in the weight ratio of the adhesive fibers between the front surface layer and the back surface layer is less than 5% is The wear resistance was inferior and could not be used for the intended purpose of the present invention.
[0038]
Table 1. Evaluation of open-hole nonwoven fabric (Examples 1 to 3)
Table 2. Evaluation of perforated nonwoven fabric (Comparative Examples 1 to 3)
【The invention's effect】
The present invention is an apertured nonwoven fabric comprising 5 to 30% by weight of adhesive fibers and 70 to 95% by weight of fibers other than the adhesive fibers, wherein the fibers are three-dimensionally entangled, A perforated nonwoven fabric characterized in that the weight ratio of the adhesive fibers is different by 5% or more between the front surface layer and the back surface layer, and the adhesive fibers are bonded to each other in the surface layer and the back surface layer. In addition to the effect of maintaining flexibility by bonding and opening and the effect of improving wear resistance by fiber bonding treatment, by distributing the layer with many adhesion points on one side, wear resistance equivalent to the wear resistance when not unevenly distributed The effect of softening the texture while maintaining both properties can be obtained, so wipes cloth, diaper members, wall coverings, interior materials, gauze, draining sheets and bags, drainage dust removal sheets, simple liquid filters , Mask inside It is possible to provide a suitable opening nonwoven fabric or the like. In addition, when the apertured nonwoven fabric of the present invention is used for a wipe, it is possible to catch dust in the aperture part, and the contact area between the apertured nonwoven fabric and the surface to be wiped is reduced, so that resistance due to friction is reduced. There is little and is easy to wipe off. For this reason, the apertured nonwoven fabric of the present invention is particularly suitable for wipes.
Claims (6)
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| JP2000295560A JP4446579B2 (en) | 2000-09-28 | 2000-09-28 | Perforated nonwoven fabric and method for producing the same |
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| JP2000295560A JP4446579B2 (en) | 2000-09-28 | 2000-09-28 | Perforated nonwoven fabric and method for producing the same |
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Families Citing this family (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6984276B2 (en) * | 2001-12-21 | 2006-01-10 | Invista North America S.Arl. | Method for preparing high bulk composite sheets |
| JP4570126B2 (en) * | 2003-12-22 | 2010-10-27 | 日本エー・シー・ピー株式会社 | Sanitary mask |
| JP4627447B2 (en) * | 2004-09-22 | 2011-02-09 | 日本バイリーン株式会社 | Filter element |
| JP4885048B2 (en) * | 2007-04-24 | 2012-02-29 | フロンティア産業株式会社 | Manufacturing method of deodorizing air filter |
| JP5525179B2 (en) * | 2008-04-28 | 2014-06-18 | ダイワボウホールディングス株式会社 | Nonwoven fabric, method for producing the same, and wiping material |
| JP2011229871A (en) * | 2010-04-08 | 2011-11-17 | Kikuo Yamada | Cleaning sheet |
| JP6705617B2 (en) * | 2014-06-23 | 2020-06-03 | 旭化成アドバンス株式会社 | Wet wiper |
| JP6685589B2 (en) * | 2015-12-21 | 2020-04-22 | タイガースポリマー株式会社 | Non-woven filter material and air cleaner element |
| JP7382722B2 (en) * | 2019-02-19 | 2023-11-17 | 白元アース株式会社 | 3D mask |
| JP2019107521A (en) * | 2019-03-18 | 2019-07-04 | 旭化成アドバンス株式会社 | Wet wiper |
| CN116801755A (en) * | 2021-01-28 | 2023-09-22 | 花王株式会社 | Sanitary mask sheet |
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