JP2954798B2 - Nonwoven fabric manufacturing method - Google Patents

Nonwoven fabric manufacturing method

Info

Publication number
JP2954798B2
JP2954798B2 JP31872092A JP31872092A JP2954798B2 JP 2954798 B2 JP2954798 B2 JP 2954798B2 JP 31872092 A JP31872092 A JP 31872092A JP 31872092 A JP31872092 A JP 31872092A JP 2954798 B2 JP2954798 B2 JP 2954798B2
Authority
JP
Japan
Prior art keywords
fiber
fibers
denier
web
splittable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
JP31872092A
Other languages
Japanese (ja)
Other versions
JPH06166936A (en
Inventor
哲 野崎
茂夫 今井
勝司 冨田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
YUNI CHAAMU KK
Original Assignee
YUNI CHAAMU KK
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by YUNI CHAAMU KK filed Critical YUNI CHAAMU KK
Priority to JP31872092A priority Critical patent/JP2954798B2/en
Publication of JPH06166936A publication Critical patent/JPH06166936A/en
Application granted granted Critical
Publication of JP2954798B2 publication Critical patent/JP2954798B2/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【0001】[0001]

【産業上の利用分野】この発明は、フィルター(瀘材)
や衣類の保温材などに好適な比較的繊度の小さい嵩高な
不織布に関する。
BACKGROUND OF THE INVENTION The present invention relates to a filter (filter material).
The present invention relates to a bulky nonwoven fabric having relatively small fineness and suitable for use as a heat insulating material for clothing and clothing.

【0002】[0002]

【従来の技術】従来、1デニール以下の比較的細デニー
ルの繊維からなる不織布がフィルター(瀘材)や衣類の
保温材などとして利用されている。細デニールの繊維に
よって嵩高なフィルターをつくると、通気抵抗が小さ
く、しかも通気の接触面積が大きいすぐれたフィルター
を得ることができる。同様に細デニールで嵩高な保温材
は、一般にしなやかであって、しかも空気容量が大き
く、ドレープ性と保温性のよい衣類を得ることができ
る。
2. Description of the Related Art Conventionally, nonwoven fabrics made of fibers having a relatively small denier of 1 denier or less have been used as filters (filter materials) and insulation materials for clothes. When a bulky filter is made of fine denier fibers, an excellent filter having a small airflow resistance and a large air contact area can be obtained. Similarly, a fine denier and bulky heat insulating material is generally supple, has a large air capacity, and can provide clothing with good drape and heat insulating properties.

【0003】一方、本発明方法に用いる易分割性の複合
繊維を高圧柱状水流で処理することにより、1デニール
以下の繊維からなる不織布を製造する方法が特開昭62
−129054号により提案されている。
On the other hand, a method for producing a nonwoven fabric comprising fibers of 1 denier or less by treating the easily splittable conjugate fiber used in the method of the present invention with a high-pressure columnar water stream has been disclosed in Japanese Patent Application Laid-Open No. Sho 62 (1987).
-129054.

【0004】[0004]

【発明が解決しようとする課題】細デニールの繊維から
なる不織布は、その繊維長にもよるが、一般にそれを製
造・使用する過程において地合いが安定せず、所要の形
態・厚みを維持することが難しい。例えば、嵩高につく
った不織布が徐々に詰まり、所要の密度よりも高密度の
ものへと変化してしまうことがある。その結果、この不
織布をフィルターとして使用した場合には、通気抵抗が
高くなり易いという問題や、保温材として使用した場合
には、空気容量が小さくなり保温性能が低下するという
問題を生ずる。また、1デニール以下の繊維は、カード
性が悪く、この繊維から嵩高な不織布を効率よく生産す
ることが難しいという問題もある。
A non-woven fabric made of fine denier fibers depends on the length of the fibers, but generally has an unstable texture during the production and use of the non-woven fabric and maintains a required form and thickness. Is difficult. For example, a bulky nonwoven fabric may gradually become clogged and change to a higher density than required density. As a result, when this nonwoven fabric is used as a filter, there is a problem that airflow resistance tends to be high, and when this nonwoven fabric is used as a heat insulating material, there is a problem that air capacity becomes small and heat insulating performance is deteriorated. In addition, fibers having a denier of 1 denier or less have a problem that the cardability is poor and it is difficult to efficiently produce a bulky nonwoven fabric from these fibers.

【0005】そこで、この発明では、1デニール以上の
易分割性繊維を含む繊維ウェブを予め融着し、その後に
分割処理して地合いの安定した嵩高な不織布の製造を可
能にし、前記従来技術の問題を解決することを課題にし
ている。
Therefore, in the present invention, a fibrous web containing easily splittable fibers having a denier of 1 denier or more is fused in advance, and then divided to produce a bulky nonwoven fabric having a stable formation and a high density. The task is to solve the problem.

【0006】[0006]

【課題を解決するための手段】この発明が前記課題を解
決するために要旨とするところは、繊維方向に連続する
複数の層に分離している繊度1デニール以上の易分割性
繊維を30重量%以上含み、かつ、1デニール以上の熱
溶融性繊維を30重量%以上含む繊維ウェブを、このウ
ェブに対する融着域の面積占有率が0.5〜30%とな
るように間欠的に融着した後、その融着したウェブを分
割処理することにより、前記易分割性繊維の少なくとも
一部を0.7デニール以下の繊度に分割することにあ
る。
The gist of the present invention to solve the above-mentioned problem is that 30-weight easily splittable fibers having a fineness of 1 denier or more separated into a plurality of layers continuous in the fiber direction. % And at least 30% by weight of heat-fusible fibers of 1 denier or more are intermittently fused so that the area occupation ratio of the fusion zone to the web is 0.5 to 30%. After that, at least a part of the easily splittable fiber is divided into fineness of 0.7 denier or less by dividing the fused web.

【0007】この発明の好ましい実施態様においては、
前記易分割性繊維が、融点の異なる複数成分の重合体か
らなる分割型複合繊維であり、かつ、前記熱溶融性繊維
が、前記易分割性繊維とは別の繊維であり、前記融着を
前記全ての繊維中最も融点の低い繊維成分によってなす
製造方法と、前記易分割性繊維が、複数本の繊維を糊剤
で集束したものであり、かつ、前記熱溶融性繊維が、前
記易分割性繊維とは別の繊維であり、前記融着を前記全
ての繊維中最も融点の低い繊維成分によってなす製造方
法と、前記分割処理が、融着したウェブを支持体上にお
いて背圧30〜100kg/cm2の高圧柱状水流で噴
射処理する工程を含んでいる。
[0007] In a preferred embodiment of the present invention,
Whether the easily splittable fiber is a polymer of a plurality of components having different melting points.
And the heat-fusible fiber
However, it is a fiber different from the easily splittable fiber,
The fiber component with the lowest melting point of all the fibers
The manufacturing method, wherein the easily splittable fiber is used as a glue for a plurality of fibers.
And the heat-fusible fiber is
This is a fiber different from the easily splittable fiber, and
Manufacturing method using the fiber component with the lowest melting point in all fibers
And the splitting step includes a step of jetting the fused web on a support with a high-pressure columnar water stream having a back pressure of 30 to 100 kg / cm 2 .

【0008】[0008]

【作用】この発明においては、易分割性繊維を使用す
る。この易分割性繊維とは、後記分割処理によって細デ
ニールの多数の繊維に分割可能な繊維をいう。かかる繊
維を含み、かつ、熱溶融性繊維を含む繊維ウェブは、こ
れをまず間欠的に融着することによって地合いが安定す
る。その後にウェブを分割処理して得られる細デニール
の繊維を含む不織布もまた地合いが安定しており、所要
の形態・厚みを維持することが容易となる。
In the present invention, easily splittable fibers are used. The easily splittable fiber is a fiber that can be split into a large number of fine denier fibers by a splitting process described later. The fibrous web containing such fibers and containing the heat-meltable fibers is firstly intermittently fused to stabilize the formation. The nonwoven fabric containing fine denier fibers obtained by dividing the web thereafter is also stable in texture and can easily maintain the required form and thickness.

【0009】[0009]

【実施例】この発明の実施態様を説明すると、以下のと
おりである。
DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below.

【0010】図1は、この発明に係る方法によって得た
不織布1の斜視図であり、(A)と(B)とによって異
なる熱融着の状態を示す。不織布1は、0.7デニール
以下に分割されている易分割性の熱可塑性繊維2と、こ
の繊維2に混在する5デニールのレーヨン繊維3とから
なり、繊維2を熱溶融してなる融着域4が間欠的に設け
てある。融着域4が、(A)では点状に分布し、(B)
では複数条をなしている。
FIG. 1 is a perspective view of a nonwoven fabric 1 obtained by the method according to the present invention, and shows different states of heat fusion between (A) and (B). The nonwoven fabric 1 is composed of easily splittable thermoplastic fibers 2 divided into 0.7 denier or less, and 5 denier rayon fibers 3 mixed in the fibers 2. Region 4 is provided intermittently. The fusion zone 4 is distributed in a point shape in (A), and (B)
Has multiple articles.

【0011】この発明において、不織布1を得るために
使用する易分割性繊維2の一例は、分割型複合繊維であ
って、この繊維は、互いに接着性の乏しい二種の熱可塑
性重合体成分、例えば、ポリエステル/ポリプロピレ
ン、ポリエステル/ナイロンなどを複合紡糸・延伸する
ことにより、各成分が繊維方向に連続する複数の層を形
成し、叩打、緊張、圧縮または熱収縮などの物理的力に
より比較的容易に分割し得るものである。分割型複合繊
維の単繊維5の横断面は、例えば図2の(A)、(B)
のように、重合体成分5a,5bからなっており、この
種の分割型複合繊維は、特公昭39−29636号、特
開昭50−5650号の各公報に開示の技術で製造する
ことができる。
In the present invention, one example of the easily splittable fiber 2 used to obtain the nonwoven fabric 1 is a splittable conjugate fiber, which is composed of two thermoplastic polymer components having poor adhesion to each other. For example, polyester / polypropylene, polyester / nylon, etc. are formed into a plurality of layers continuous in the fiber direction by composite spinning / drawing, and are relatively hardened by physical force such as beating, tension, compression or heat shrinkage. It can be easily divided. The cross-section of the single fiber 5 of the splittable conjugate fiber is, for example, as shown in FIGS.
As described above, this type of splittable conjugate fiber is composed of polymer components 5a and 5b, and can be produced by the techniques disclosed in JP-B-39-29636 and JP-A-50-5650. it can.

【0012】図3は、不織布1の模式的製造工程図であ
る。この工程においては、まずランダムウェブ機10に
より、ポリエステル/ポリプロピレンからなる3デニー
ルの分割型複合繊維2Aを90重量%と5デニールのレ
ーヨン繊維7を10重量%混合してなる繊維ウェブ11
を熱エンボスロール12に供給する。エンボスロール1
2はポリプロピレンの溶融温度以上、ポリエステルの溶
融温度以下に加熱してポリプロピレンを溶融することに
よりウェブ11に対し直径2mmの融着域4をMD、C
D両方向に10mmピッチで付与し、融着ウェブ13と
する。融着ウェブ13は、水流処理装置15へ送り、支
持体16上において、ノズル手段17に設けた多数の微
小オリフィスから高速水流18を噴射し、分割型複合繊
維2Aを、融着域4を除く非融着域において、0.7デ
ニール以下の繊維に分割して不織布1を得る。効率よく
分割するには、噴射距離や時間にもよるが、噴射背圧を
30〜100kg/cm2にすることが好ましい。水流
処理装置15による処理については、特開昭62−12
9054号の公開公報に開示の技術を利用することがで
きる。不織布1は、さらに、無端ベルト20にせて熱
風乾燥機21で乾燥した後、ロール22に巻取る。
お、ウェブ11に対し直径2mmの融着域4をMD、C
D両方向に10mmピッチで付与して高速水流で処理す
ると、各融着域 4間の繊維は交絡することがない。
FIG. 3 is a schematic manufacturing process diagram of the nonwoven fabric 1. In this step, first, a random web machine 10 mixes 90% by weight of 3-denier splittable conjugate fiber 2A made of polyester / polypropylene and 10% by weight of 5-denier rayon fiber 7 in 10% by weight.
Is supplied to the hot embossing roll 12. Embossing roll 1
Reference numeral 2 denotes a fusion zone 4 having a diameter of 2 mm with respect to the web 11 by heating at a temperature higher than the melting temperature of polypropylene and lower than the melting temperature of polyester to melt the polypropylene.
D Apply at a pitch of 10 mm in both directions to form a fused web 13. The fusion web 13 is sent to a water flow treatment device 15, and a high-speed water flow 18 is jetted from a large number of micro orifices provided on a nozzle means 17 on a support 16 to remove the splittable conjugate fiber 2 </ b> A and remove the fusion area 4. In the non-fused area, the non-woven fabric 1 is divided into fibers of 0.7 denier or less. For efficient division, the injection back pressure is preferably set to 30 to 100 kg / cm 2 , although it depends on the injection distance and time. The processing by the water flow treatment device 15 is described in JP-A-62-12
The technology disclosed in Japanese Patent Publication No. 9054 can be used. Nonwoven fabric 1 further includes after by placing the endless belt 20 and dried in a hot air dryer 21 takes a roll 22 wound. What
In addition, the fusion zone 4 having a diameter of 2 mm is formed on the web 11 by MD and C.
D Apply at 10mm pitch in both directions and treat with high-speed water flow
Then, the fibers between the fusion zones 4 do not become entangled.

【0013】図3の工程において、易分割性繊維2に
は、分割型複合繊維2Aに代え、1デニール以下の複数
本の繊維をポバールなどの糊剤で集束させた、いわゆる
集束繊維を利用することもできる。易分割性繊維2は、
繊維ウェブ11に対し30重量%以上であることが好ま
しく、それによりフィルターや保温材に好適な嵩高な不
織布1を得ることが容易になる。また、ウェブ11にお
いて熱溶融性繊維が30重量%以上を占めることも必要
であり、それにより熱エンボスによる融着域を確実に形
成することができる。これらの易分割性繊維2や熱溶融
性繊維には、1デニール以上のものを使用し、ランダム
ウェブ機10による繊維ウェブ11の製造を容易にする
ことが好ましい。なお、熱溶融性繊維は、これを分割型
複合繊維2Aが兼ねていてもよいが、必要ならこの繊維
2Aとは異なる熱溶融特性を有する1デニール以上の別
の繊維にすることができる。熱エンボスの条件につい
て、繊維ウェブ11が分割型複合繊維2Aの如く、融点
の異なる2成分以上の重合体を含む場合には、融点の最
も低い成分だけを溶融させることが好ましい。熱エンボ
スは、繊維ウェブ11や不織布1の地合いを安定させる
ことが目的であって、図1(A)のように融着域4を点
在させるときには、一つの融着域4の面積が0.5〜1
00mm2で、全融着域4のウェブ11および不織布1
に対する面積占有率が0.5〜30%となるようにした
うえで、一様に分布させると、地合いを安定させる効果
が高くなる。図1(B)の複数条の融着域4において
も、面積占有率を0.5〜30%の範囲におさめる。占
有率が30%を越えると不織布1が硬くなり、実用に適
さなくなる。易分割性繊維2が集束繊維である場合に
は、繊維を解束して細デニールにする分割手段として、
水流処理装置15を利用する他に、糊剤の性状に応じ、
繊維を浴槽に浸漬するなどの周知の糊抜き技術を利用す
ることができる。
In the step shown in FIG. 3, so-called bundled fibers, in which a plurality of fibers of 1 denier or less are bundled with a glue such as poval, are used as the easily splittable fibers 2 instead of the splittable conjugate fibers 2A. You can also. The easily splittable fiber 2 is
The content is preferably 30% by weight or more based on the fibrous web 11, whereby it becomes easy to obtain a bulky nonwoven fabric 1 suitable for a filter or a heat insulating material. Further, it is necessary that the heat-meltable fibers occupy 30% by weight or more in the web 11, so that a fusion zone by hot embossing can be reliably formed. It is preferable to use a fiber of 1 denier or more as the easily splittable fiber 2 or the heat-meltable fiber to facilitate the production of the fibrous web 11 by the random web machine 10. The splittable composite fiber 2A may also serve as the heat-meltable fiber, but if necessary, it may be another fiber of 1 denier or more having a different heat-melting property from the fiber 2A. Regarding the conditions of the hot embossing, when the fiber web 11 contains two or more polymers having different melting points, such as the splittable conjugate fiber 2A, it is preferable to melt only the component having the lowest melting point. The purpose of the heat embossing is to stabilize the formation of the fibrous web 11 and the nonwoven fabric 1, and when the fused areas 4 are scattered as shown in FIG. 0.5-1
00 mm 2 , the web 11 and the nonwoven fabric 1 in the entire fusion zone 4
If the area occupation ratio is set to 0.5 to 30% and uniformly distributed, the effect of stabilizing the formation increases. The area occupation ratio is set in the range of 0.5 to 30% also in the plurality of fusion zones 4 in FIG. If the occupation ratio exceeds 30%, the nonwoven fabric 1 becomes hard and is not suitable for practical use. When the easily splittable fiber 2 is a bundled fiber, as a splitting means for unbunching the fiber to fine denier,
In addition to using the water treatment device 15, depending on the properties of the paste,
Well-known desizing techniques, such as dipping the fibers in a bath, can be used.

【0014】不織布1が、強度を必要とする場合には、
相対的に太デニールの非分割性繊維を混在させることが
できる他に、レーヨン繊維などの非溶融性繊維を混在さ
せ、親水性その他の特性を付与することもできる。ただ
し、いずれの場合においても1デニール以上の繊維を使
用し、カード機などによる繊維ウェブの形成を容易にす
ることが好ましい。
When the nonwoven fabric 1 needs strength,
In addition to being able to mix relatively thick denier non-dividing fibers, non-melting fibers such as rayon fibers can be mixed to impart hydrophilicity and other properties. However, in any case, it is preferable to use fibers of 1 denier or more to facilitate the formation of a fibrous web by a card machine or the like.

【0015】[0015]

【発明の効果】このように構成した不織布の製造方法で
は、繊維ウェブが予め融着しているから地合いが安定
し、その後の繊維分割処理によって、例えば高圧柱状水
流を噴射しても、ウェブの形態・厚みが著しく変化する
ことがなく、より高圧の水流を作用させて、より細デニ
ールに分割することが容易になる。得られた不織布も地
合いが安定しているから、使用過程において所要の形態
・厚みを損なうことがない。
According to the method for manufacturing a nonwoven fabric having the above-described structure, the formation is stabilized because the fibrous web is fused in advance, and even if, for example, a high-pressure columnar water stream is jetted by the subsequent fiber division processing. The shape and thickness are not significantly changed, and it is easy to divide into fine deniers by applying a higher pressure water flow. Since the obtained nonwoven fabric also has a stable formation, the required form and thickness are not impaired in the course of use.

【図面の簡単な説明】[Brief description of the drawings]

【図1】不織布の斜視図、(A)と(B)とによって熱
融着の異なる態様を示す。
FIG. 1 is a perspective view of a nonwoven fabric, showing different modes of heat fusion depending on (A) and (B).

【図2】分割型複合繊維の断面図、(A)と(B)とに
よって、断面模様の異なる繊維を示す。
FIG. 2 is a cross-sectional view of a splittable conjugate fiber, showing fibers having different cross-sectional patterns depending on (A) and (B).

【図3】不織布の模式的製造工程図。FIG. 3 is a schematic production process diagram of a nonwoven fabric.

【符号の説明】[Explanation of symbols]

1 不織布 2 易分割性繊維 2A 易分割性繊維 15 分割手段(水流処理装置) 16 支持体 18 柱状水流 DESCRIPTION OF SYMBOLS 1 Nonwoven fabric 2 Easily separable fiber 2A Easily separable fiber 15 Division | segmentation means (water flow treatment apparatus) 16 Support body 18 Column-shaped water flow

Claims (4)

(57)【特許請求の範囲】(57) [Claims] 【請求項1】繊維方向に連続する複数の層に分離してい
る繊度1デニール以上の易分割性繊維を30重量%以上
含み、かつ、繊度1デニール以上の熱溶融性繊維を30
重量%以上含む繊維ウェブを、該ウェブに対する融着域
の面積占有率が0.5〜30%となるように間欠的に融
着した後、該ウェブを分割処理して前記易分割性繊維の
少なくとも一部を0.7デニール以下の繊度に分割する
ことを特徴とする不織布の製造方法。
1. A method according to claim 1, wherein 30% by weight or more of easily splittable fibers having a fineness of 1 denier or more, which are separated into a plurality of layers continuous in the fiber direction, and 30% by weight of heat-fusible fibers having a fineness of 1 denier or more.
After intermittently fusing a fibrous web containing not less than 0.5% by weight so that the area occupation ratio of the fusing area to the web is 0.5 to 30%, the web is subjected to a splitting treatment so that the easily splittable fiber A method for producing a nonwoven fabric, wherein at least a part is divided into fineness of 0.7 denier or less.
【請求項2】前記易分割性繊維が、融点の異なる複数成
分の重合体からなる分割型複合繊維であり、かつ、前記
熱溶融性繊維が、前記易分割性繊維とは別の繊維であ
り、前記融着を前記全ての繊維中最も融点の低い繊維成
分によってなす請求項1に記載の製造方法。
2. A fiber according to claim 1, wherein said easily splittable fibers have different melting points.
Is a splittable composite fiber made of a polymer of
The heat-meltable fiber is a fiber different from the easily splittable fiber.
The fusion is performed with the fiber component having the lowest melting point among all the fibers.
The production method according to claim 1, wherein the production is performed in minutes.
【請求項3】前記易分割性繊維が、複数本の繊維を糊剤
で集束したものであり、かつ、前記熱溶融性繊維が、前
記易分割性繊維とは別の繊維であり、前記融着を前記全
ての繊維中最も融点の低い繊維成分によってなす請求項
1に記載の製造方法。
3. The method according to claim 1, wherein the easily splittable fiber is a plurality of fibers
And the heat-fusible fiber is
This is a fiber different from the easily splittable fiber, and
Claims made by the fiber component with the lowest melting point in all fibers
2. The production method according to 1.
【請求項4】前記分割処理が、前記融着したウェブを支
持体上において背圧30〜100kg/cm2の高圧柱
状水流で噴射処理する工程を含む請求項1ないし3に
載の製造方法。
Wherein said division processing is serial to claims 1 to 3 comprising the step of injecting treated with high pressure columnar water streams back pressure 30~100kg / cm 2 on the support the fused web <br/> Manufacturing method.
JP31872092A 1992-11-27 1992-11-27 Nonwoven fabric manufacturing method Expired - Lifetime JP2954798B2 (en)

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Application Number Priority Date Filing Date Title
JP31872092A JP2954798B2 (en) 1992-11-27 1992-11-27 Nonwoven fabric manufacturing method

Publications (2)

Publication Number Publication Date
JPH06166936A JPH06166936A (en) 1994-06-14
JP2954798B2 true JP2954798B2 (en) 1999-09-27

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6200669B1 (en) * 1996-11-26 2001-03-13 Kimberly-Clark Worldwide, Inc. Entangled nonwoven fabrics and methods for forming the same

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