JP3464544B2 - Method for producing thin and lightweight reinforced hydroentangled nonwoven fabric - Google Patents
Method for producing thin and lightweight reinforced hydroentangled nonwoven fabricInfo
- Publication number
- JP3464544B2 JP3464544B2 JP26844794A JP26844794A JP3464544B2 JP 3464544 B2 JP3464544 B2 JP 3464544B2 JP 26844794 A JP26844794 A JP 26844794A JP 26844794 A JP26844794 A JP 26844794A JP 3464544 B2 JP3464544 B2 JP 3464544B2
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- long
- stretched
- fiber nonwoven
- fibers
- 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 - Fee Related
Links
Landscapes
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Description
【発明の詳細な説明】
【０００１】
【産業上の利用分野】本発明は、薄手軽量でドレープ性
および柔軟性があり、かつ縦横の強度バランスが改良さ
れた強化水流絡合不織布およびウエブ形成工程や水流絡
合工程が本来有している高速生産性を低下させない上記
不織布の製造方法に関するものである。更に詳しくは、
芯地等の衣料製品、フィルターや工業用ワイパー等の産
業用資材、および手術衣、シーツ、タオル、マスク等の
メディカルディスポーザブル製品等に広く用いられる薄
手軽量強化水流絡合不織布およびその製造方法に関する
ものである。
【０００２】
【従来の技術】短繊維ウエブに高圧流体を噴射すること
によって、ウエブを形成する繊維を相互に絡み合わせ、
ウエブに適当な絡合構造と特定の物性とを付与する方法
は、水流絡合法として広く実施されている。水流絡合法
により製造された不織布は、繊維間に結合点がないこと
から他の不織布よりも各繊維が相互に動く自由度が大き
いので、柔軟性に富み、リントフリーであり、ドレープ
性があり、ソフトな風合いを有するものである。しか
し、繊維が互いに結合していないので、強度的には弱
く、不安定で変形し易いという欠点がある。また、高圧
流体の噴射跡がウエブの縦方向（流れ方向）に連続的に
残るため、縦方向と横方向の強度バランスが悪く、強度
バランスを改善するためにはクロスレイヤー等の工程の
追加が必要になり、必要以上の厚手になると共に、生産
性が低下するという欠点がある。このような欠点を改良
する方法として、ステープルファイバーからなる不織布
を強化基材として用いる方法（特開昭５４−８２４８１
号公報）、織物、編物または不織布からなる補強材を用
いる方法（特開昭５４−１０１９８１号公報、特開昭６
１−２２５３６１号公報）、木材パルプを強化基材に用
いる方法（特開昭５９−９４６５９号公報）、網状物に
短繊維ウエブを絡合させる方法（特開平１−３２１９６
０号公報、特開平４−２６３６６０号公報）、スパンボ
ンド不織布に短繊維ウエブを絡合させる方法（特開平４
−３３３６５２号公報、特開平４−１５３３５１号公
報）等が開示されている。
【０００３】
【発明が解決しようとする課題】しかし、これらの開示
技術に見られる強化支持体による改良方法では、いずれ
も強化の目的は達成されるが、更に水流絡合不織布の特
徴である柔軟性、リントフリー性、ドレープ性、ソフト
な風合い等を保持し、かつ薄手軽量で強度バランスの改
善された不織布を簡易で経済性に優れた方法で製造する
技術についてはまだ知られていない。また、不織布の強
度バランスを改善する目的でウエブにクロスレイヤー処
理等を行うと、一般的にウエブ層形成の生産速度は１／
２〜１／５０に低下し、後続の水流絡合工程の生産性も
低下する。水流絡合の間またはその後に同様の処理を行
っても同様に生産性の低下が起こる。ウエブ層形成工程
や水流絡合工程が本来有している高速生産性を低下させ
ずに強度バランスに優れた不織布を製造する技術もまた
知られていない。
【０００４】
【課題を解決するための手段】本発明者らは、上記の問
題点を解決するために鋭意検討した結果、天然繊維、再
生繊維または合成繊維からなるウエブ層に特定の基材を
強化支持体として重ね合わせた多層体に高圧の水流を噴
射することにより、繊維が強化支持体に絡合して縦方向
および横方向の強度バランスが改善され、かつ柔軟性、
リントフリー性、ドレープ性、ソフトな風合い等を有す
る薄手軽量強化水流絡不織布を、ウエブ形成工程および
水流絡合工程が本来有している高速生産性を低下させず
に製造し得ることを見出して本発明を完成した。すなわ
ち、本願の第１の発明は、以下の工程からなる、天然繊
維、再生繊維または合成繊維を配列したウェブ層と、長
繊維不織布を経緯直交させて積層した、延伸交差積層不
織布からなる強化支持体とを一体化させてなる、坪量
（g/m2）当たりの引張強度（g/3cm巾）が、縦方向が１
１４〜１６１、横方向が１０２〜１６９である薄手軽量
強化水流絡合不織布の製造方法を提供するものである。
１）天然繊維、再生繊維または合成繊維を配列してウェ
ブ層を製造する工程、
２）熱可塑性樹脂を紡口より噴出した溶融紡糸フィラメ
ントに熱風で旋回または振動を与えて縦方向に配列させ
ながらベルトコンベア上に集積してほぼ全量の未延伸フ
ィラメントを縦方向に配列した長繊維不織布を製造する
工程、
３）工程２）で得た長繊維不織布をロール間近接延伸に
より縦方向に５〜１２倍延伸し、平均繊度が０.０１か
ら１０デニールとした、縦延伸一方向配列長繊維不織布
を製造する工程、
４）熱可塑性樹脂を紡口より噴出した溶融紡糸フィラメ
ントに熱風で旋回または振動を与えて横方向に配列させ
ながらベルトコンベア上に集積してほぼ全量の未延伸フ
ィラメントを横方向に配列した長繊維不織布を製造する
工程、
５）工程４）で得た長繊維不織布を横延伸法により横方
向に５〜１２倍延伸し、平均繊度が０.０１から１０デ
ニールとした、横延伸一方向配列長繊維不織布を製造す
る工程、
６）工程３）で得た縦延伸一方向配列長繊維不織布と工
程５）で得た横延伸一方向配列長繊維不織布を経緯直交
させて積層した坪量が１〜８０g/m2の延伸交差積層不織
布からなる強化支持体を製造する工程、
７）工程１）で得たウェブ層と工程６）で得た強化支持
体とを積層して搬送しつつ、１０〜３００kg/cm2の高圧
水流を噴射して、処理速度２〜２００m/minで絡合加工
を施すことにより、該ウェブ層と該強化支持体とを一体
化する工程。
【０００５】以下、本発明を更に詳述する。本発明に用
いる天然繊維、再生繊維または合成繊維からなるウエブ
層は、木綿、リンター、パルプ等の天然繊維、レーヨ
ン、キュプラ等の再生セルロース繊維、アセテート等の
半合成セルロース繊維、ポリエチレン、ポリプロピレ
ン、ポリエステル、ポリアミド、ポリアクリロニトリ
ル、アクリル、ポリビニルアルコール等の合成繊維また
はポリウレタン系およびポリエステル系エラストマー繊
維、コンジュゲート繊維、高圧水流により超極細繊維に
分繊される分割型複合繊維等のいずれか、あるいはそれ
らの混合物を原料としたものである。ウエブ層を形成す
るには、再生繊維等を湿式紡糸したものまたは合成繊維
を通常の方法により溶融紡糸したものをカットし、カー
ド機により繊維を引き揃えてウエブに形成する方法、あ
るいは天然繊維をカード機により引き揃えてウエブに形
成したりまたは叩解して抄紙する方法等が用いられる。
【０００６】上記ウエブ層の繊維の単糸繊度は好ましく
は０.０１〜１５デニール、より好ましくは０.０３〜５
デニールであり、繊維の長さは好ましくは１〜１００ｍ
ｍ、より好ましくは１０〜６０ｍｍである。単糸繊度が
０.０１デニール未満ではリントフリー性に劣り、１５
デニールを超えると風合いに劣る。また繊維の長さが１
ｍｍ未満では絡合が不十分で強度が低く、１００ｍｍ
を超えると分散性が悪くなり好ましくない。また、ウエ
ブの坪量は好ましくは１０〜１５０g/m2、より好ましく
は２０〜５０g/m2である。坪量が１０g/m2未満では高圧
水流処理の際に繊維の密度にムラを生じ、また１５０g/
m2を超えると薄手軽量性に劣るものとなるため、いずれ
も好ましくない。
【０００７】本発明に用いる長繊維は、予め延伸されて
いてもよいが、更に２倍以上の２次延伸が可能であるこ
とが必要である。本発明の長繊維不織布の形成方法とし
ては種々の形式が用いられるが、熱可塑性樹脂の紡糸
フィラメントに熱風で旋回または振動を与えて縦または
横方向に配列させ、ほぼ全量の繊維が一方向に配列した
不織布を形成する方式、熱可塑性樹脂を紡糸し、延
伸、開繊、補集および絡合を行って不織布を形成する方
式（例えば、スパンボンド法）、熱可塑性樹脂を高温
高圧空気と共に噴射し開繊配列して不織布を形成する方
式（例えば、メルトブローン法）、熱可塑性樹脂の長
繊維束を延伸捲縮し、開繊および拡幅を行って不織布を
形成する方式（例えば、トウ開繊法）、熱可塑性樹脂
の発泡押出しを行い、発泡破裂、積層および延展を行っ
て不織布を形成する方式（例えば、バーストファイバー
法）等が挙げられる。
【０００８】本発明においては、強化支持体として、熱
可塑性樹脂から紡糸された長繊維不織布を一方向に延伸
してなり、かつ長繊維がほぼ一方向に配列した延伸一方
向配列不織布またはそれらの配列軸が交差するように積
層した延伸交差積層不織布を用いる。本発明の延伸とは
圧延処理も包含するものである。延伸手段としては、従
来のフィルムや不織布の延伸に使用された縦延伸手段、
横延伸手段および二軸延伸手段を使用することができ
る。すなわち、縦延伸手段としては、ロール間近接延伸
が、幅を狭めることなく延伸することができるため好適
である。他に、ロール圧延、熱風延伸、熱水延伸、蒸気
延伸等も使用することができる。横延伸手段としては、
フィルムの二軸延伸に使用されているテンター法も使用
することができるが、上記特公平３−３６９４８号公報
に例示したプーリ式横延伸法や、溝ロールを組み合わせ
た横延伸法（溝ロール法）が簡便である。二軸延伸手段
としては、フィルムの二軸延伸に使用されているテンタ
ータイプの同時二軸延伸方式も使用できるが、上記縦延
伸手段と横延伸手段とを組み合わせることによっても達
成することができる。上記延伸一方向配列不織布の延伸
倍率は５〜２０倍であり、好ましくは８〜１２倍であ
る。延伸された不織布の平均繊度は０.０１〜１０デニ
ールであり、好ましくは０.０３〜５デニールである。
単層または積層された不織布の坪量は１〜８０g/m2であ
り、好ましくは５〜３０g/m2である。本発明における強
化支持体としては、熱可塑性樹脂から紡糸された長繊維
を縦方向に延伸および配列して形成した不織布、上記長
繊維を横方向に延伸および配列して形成した不織布、そ
れらの配列軸方向を揃えて積層した不織布およびそれら
の交差積層不織布、ならびに長繊維不織布を二軸延伸し
たものなどを用いることができる。
【０００９】本発明に用いる長繊維不織布の原料とする
熱可塑性樹脂としては、高密度、中密度および低密度ポ
リエチレン、線状低密度ポリエチレン、超低密度ポリエ
チレン、ポリプロピレンやプロピレン−エチレン共重合
体等のプロピレン系重合体、α−オレフィン重合体、ポ
リアミド、ポリエステル、ポリカーボネート、ポリビニ
ルアルコール等が挙げられるが、ポリプロピレンおよび
ポリエステルが特に好ましい。酸化防止剤、紫外線吸収
剤、滑剤などを樹脂に添加して使用することも可能であ
る。
【００１０】本発明における天然系繊維、再生繊維また
は合成繊維からなるウエブ層と強化支持体の組合せとし
ては、繊維ウエブ層（Ａ）と強化支持体（Ｂ）を交互に
重ねて構成した２層以上のものを用いることができる。
例えばＡ/Ｂ、Ａ/Ｂ/Ａ、Ｂ/Ａ/Ｂ、Ａ/Ｂ/Ａ/Ｂ等の任
意の組合せが可能である。
【００１１】次に、本発明の薄手軽量強化水流絡合不織
布の製造方法について詳述する。その製造方法は、
（１）ウエブ層形成工程、（２）ウエブ層と強化支持体
とを重ね合わせながら供給する積層供給工程、（３）水
の噴射処理を行う高圧水流絡合工程、（４）乾燥工程、
および（５）製品巻取工程から構成される。
【００１２】まず、（１）ウエブ層形成工程において
は、原料の種類および最終用途によりウエブの配列や形
成の方法として種々の形式が用いられる。ウエブの特性
としては、平面内および厚さ方向のすべてに繊維の分散
が均質で規則正しいことが要求され、ウエブの繊維配列
方法としては、縦方向に二次元配列した機械式カード
ウエブ形成法によるカード・パラレル方式、二次元と
三次元の中間配列のセミランダム機によるセミランダム
方式、繊維をエアーブローに乗せて飛ばし、メッシュ
スクリーン上に集積するランダム方式、樹脂を乾式ま
たは湿式で紡糸し、延伸、開繊、補集および絡合を行う
連続ウエブ形成法によるスパンボンド方式、天然繊
維、再生繊維等を叩解して抄紙した湿式ウエブ形成法等
が挙げられる。なお、生産速度が幾分低下するが、三方
向の強度バランスを得るために斜方向に交差配列した機
械式クロスウエブ形成法によるカード・クロスレイヤー
方式を挙げることもできる。
【００１３】図１は、上記工程のうち、（２）積層供給
工程以降の工程の一例を示す概略図である。積層供給工
程においては、予め巻取られたウエブ層１および強化支
持体２を製品の構成に従って各供給ロール１ａおよび２
ａから繰り出す。この方法はオフマシン方法であるが、
（１）ウエブ層形成工程の繊維補集部において製品の構
成に従いウエブ層と強化支持体を重ね合わせ（図示せ
ず）、後続の高圧水流絡合工程に連続的に給送するオン
マシン方法により製造することもできる。
【００１４】次の（３）高圧水流絡合工程では、処理水
透過性または不透過性の移送用支持体３としてのスクリ
ーンまたはロールの上で、給送されたウエブ層と強化支
持体の積層体４に、高圧水流小径ノズル列５から細い水
流５ａを噴射する。なお、水流を噴射する前に、上記積
層体を浸水装置６において予め水６ａに浸し、また水流
噴射後には、減圧吸引手段などを設けた水分吸引装置７
により水分を除去することが作業の効率を高める上で好
ましい。なお、水流絡合を効果的に行うために、ウエブ
層積層体の両面から高圧水流絡合を施すことが望まし
い。すなわち、第１の移送用支持体３を離れたウエブ層
の積層体４を、第２の移送用支持体３ａの上に導き、高
圧水流小径ノズル列５ｂから細い水流５ｃを噴射し、先
に水流５ａにより絡合した面の反対側の面から高圧水流
絡合を施す。
【００１５】高圧水流絡合工程において、高圧水流処理
をスクリーン上で行う場合、スクリーンは特に限定され
ないが、処理水の排出処理を容易にするために、目的や
用途等に合わせて材質、網目寸法、線径等を選択するこ
とが好ましい。網目寸法は通常２０〜２００メッシュで
ある。処理水透過性の移送用支持体を用いる方法におい
ては、処理水が容易に排出されるため、水流の噴射によ
りウエブを飛散させて均一性を損なうことが避けられ
る。しかしながら、一旦ウエブを通過した処理水にはま
だかなりのエネルギーが残存しており、エネルギー効率
が高くない。一方、処理水不透過性の移送用支持体を用
いる方法においては、ウエブを透過した噴射水流は、移
送用支持体に衝突して反発流となり再びウエブに作用す
るため、噴射流と反発流の相互作用により絡合が効率よ
く行われる。しかしながら、水中に浮遊しているウエブ
に高圧水流を噴射する状態となるため、絡合の安定性が
低くなる欠点がある。これらの内では、処理水透過性の
移送用支持体上で高圧水流の噴射処理を行う方法が好ま
しい。
【００１６】噴射水流は、移送方向に対し垂直の方向か
ら、０.２ｍｍ以上のピッチで列状に配列された小径ノ
ズル列から噴射される。小径ノズルのオリフィス径は１
ｍｍ以下であり、０.１〜０.５ｍｍが好ましい。噴射さ
れる液体は水が好ましく、衛生上必要な場合には熱水や
超純水を用いてもよい。噴射水流の圧力は１０〜３００
kg/cm2であり、好ましくは２０〜２００kg/cm2である。
圧力が１０kg/cm2未満では絡合効果が不十分であり、ま
た３００kg/cm2を超えると高圧水流のコストが増大する
上に、取扱いが困難であるため、いずれも好ましくな
い。噴射は１回以上行うが、小径ノズル列を数列配置
し、段階的に噴射水圧を上げて絡合させる方法が好まし
い。すなわち、第一段目は低圧で表面層を交絡させ、次
に続く小径ノズル列で水圧を上げながら、中間層から下
層へと交絡を進めることにより、乱れのない水流絡合不
織布を効率よく得ることができる。また、ウエブ層の材
質、形状、坪量や処理回数などに応じて、低圧法（２０
〜５５kg/cm2）、中圧法（５５〜９０kg/cm2）および高
圧法（９０〜２００kg/cm2）の中から自由に選択するこ
とができる。高圧流体の形状は特に限定しないが、エネ
ルギー効率の点から柱状流が好ましい。柱状流の断面形
状は、小径ノズルの断面形状あるいは内部構造により決
定されるが、ウエブの材質、目的、用途等に応じて自由
に選択することができる。水流絡合工程の処理速度は２
〜２００m/min であり、好ましくは５０〜１５０m/min
である。処理速度が２m/min 未満では生産性が低く、ま
た２００m/min を超えると絡合効果が不十分であるた
め、いずれも好ましくない。
【００１７】高圧水流の噴射により絡合処理したウエブ
層と強化支持体とからなる積層体は、例えばオーブン
８、熱風炉または熱シリンダー等による（４）乾燥工程
を経て、（５）製品巻取工程において薄手軽量強化水流
絡合不織布９として巻取る。
【００１８】
【作用】本発明の薄手軽量強化水流絡合不織布は、長繊
維不織布を一方向に延伸し、かつ繊維をほぼ同一方向に
配列させた延伸不織布またはそれらを交差積層した不織
布からなる強化支持体により補強されているため、薄手
軽量であるにもかかわらず高い強度を有しており、これ
は従来の水流絡合不織布では達成することができなかっ
た優れた長所である。また、強化支持体として、縦方向
のみに高い強度を有する不織布、横方向のみに高い強度
を有する不織布および縦横の強度バランスに優れた不織
布を自由に選択することが可能であり、用途に合わせた
強度バランスを最終製品に付与することができる。従来
の多くの不織布に見られるように、縦横の強度バランス
に無理が生じたり、縦強度が過大になるようなことはな
く、縦横の強度バランスを任意に調節した製品を提供す
ることができる。
【００１９】
【実施例】以下、本発明を実施例により説明する。
＜実施例１、比較例１＞繊度２デニール、長さ５０ｍｍ
および平均坪量２０g/m2のレーヨン短繊維をカード・パ
ラレル方式により二次元配列してウエブ層（Ｗ1）とし
た。ポリエチレンテレフタレート（ＰＥＴ）樹脂（商品
名：ＭＡ ２１００、ユニチカ(株)製）を原料とし、紡
口より噴出する溶融紡糸フィラメントに熱風で旋回を与
えて縦方向に配列させながら、循環走行する網状無端ベ
ルトコンベヤ上に集積して、繊度が２デニールの未延伸
フィラメントが縦方向に配列した長繊維不織布を得た。
次いで、この不織布をロール間近接延伸により縦方向に
１０倍に延伸して繊度０.２デニールとし、ポリビニル
アルコールによる仮接着を行って坪量８ g/m2の縦延伸
一方向配列長繊維不織布（Ａ1）を得た。また同じ樹脂
を同様に紡糸し、横方向に配列した長繊維不織布を作製
し、プーリ式横延伸法により横方向に１０倍に延伸して
繊度０.２デニールとし、ポリビニルアルコールによる
仮接着を行って坪量８g/m2の横延伸一方向配列長繊維不
織布（Ｂ1）を得た。不織布Ａ1および不織布Ｂ1を経緯
直交させて積層し、ポリビニルアルコールによる仮接着
を行い坪量１５g/m2の延伸交差積層不織布（Ｃ1）を得
た。また、不織布Ａ1および不織布Ｂ1を経緯直交させて
積層し、熱エンボス加工を行い坪量１４g/m2の延伸交差
積層不織布（Ｄ1）を得た。これらの不織布を強化支持
体として使用した。ウエブ層と強化支持体との層構成が
Ｗ1/Ａ1/Ｗ1、Ｗ1/Ｂ1/Ｗ1、Ｗ1/Ｂ1/Ｂ1/Ｗ1、Ｗ1/Ｃ1
/Ｗ1およびＷ1/Ｄ1/Ｗ1となるように重ね合わせ、１０
０メッシュの金網を備えた処理水透過性のスクリーンか
らなる無端ベルトコンベヤ上に給送し、上方より、オリ
フィス径０.１５ｍｍ、ピッチ１.０ｍｍで多数の小径ノ
ズルを備えた３列のノズル列を通して、第１列７０kg/c
m2、第２列９０kg/cm2および第３列１１０kg/cm2の圧力
で高圧水流を噴射しながら１００m/min の速度で表側か
ら１回、裏側から更に１回絡合処理を行った後、乾燥し
て薄手軽量強化水流絡合不織布を得た。比較例１とし
て、本実施例と同じ坪量のレーヨン短繊維ウエブ
（Ｗ1）のみを用い、同じ条件で水流絡合処理を行っ
た。これらの物性を表１に示す。
【００２０】
【表１】
【００２１】＜実施例２、比較例２＞繊度２デニール、
長さ５０ｍｍおよび平均坪量２０g/m2のポリプロピレン
（商品名：日石ポリプロ Ｊ１２０、日本石油化学(株)
製）の短繊維を、カード・パラレル方式により二次元配
列してウエブ層（Ｗ2）とした。ポリプロピレン樹脂
（密度０.９０g/cm3、メルトフローレート７００g/10mi
n）を原料として実施例１と同様に紡糸を行い、繊度が
２デニールの未延伸フィラメントからなる縦方向に配列
した長繊維不織布を得た後、この不織布を実施例１と同
様に縦方向に延伸して繊度を０.２デニールとし、ポリ
ビニルアルコールによる仮接着を行って坪量６g/cm2の
縦延伸一方向配列長繊維不織布（Ａ2）を得た。また上
記原料から実施例１と同様にして得た横方向に配列した
長繊維不織布を、同様に横方向に延伸して繊度０.２デ
ニールとし、ポリビニルアルコールによる仮接着を行っ
て坪量６g/cm2の横延伸一方向配列長繊維不織布（Ｂ2）
を得た。不織布Ａ2および不織布Ｂ2を経緯直交させて積
層し、ポリビニルアルコールによる仮接着を行い坪量１
１g/m2の延伸交差積層不織布（Ｃ2）を得た。また、不
織布Ａ2および不織布Ｂ2を経緯直交させて積層し、熱エ
ンボス加工を行い坪量１０g/m2の延伸交差積層不織布
（Ｄ2）を得た。これらの不織布を強化支持体として使
用した。カード・パラレルウエブ形成工程の補集部に強
化支持体を給送し、層構成がＷ2/Ａ2/Ｗ2、Ｗ2/Ｂ2/
Ｗ2、Ｗ2/Ｂ2/Ｂ2/Ｗ2、Ｗ2/Ｃ2/Ｗ2およびＷ2/Ｄ2/Ｗ2
となるように重ね合わせ、１００メッシュの金網を備え
た処理水透過性のスクリーンからなる無端ベルトコンベ
ヤ上に給送し、上方より、オリフィス径０.１５ｍｍ、
ピッチ１.０ｍｍで多数の小径ノズルを備えた３列のノ
ズル列を通して、第１列 ７０kg/cm2、第２列９０kg/c
m2および第３列１１０kg/cm2の圧力で高圧水流を噴射し
ながら１００m/min の速度で表側から１回、裏側から更
に１回絡合処理を行った後、乾燥して薄手軽量強化水流
絡合不織布を得た。比較例２として、本実施例とほぼ同
じ坪量のポリプロピレン短繊維ウエブ （Ｗ2）のみを
用い、同じ条件で水流絡合処理を行った。これらの物性
を表２に示す。
【００２２】
【表２】
【００２３】＜実施例３、比較例３＞ポリウレタン系の
ストレッチ性メルトブローン不織布（商品名：エスパン
シオーネ、鐘紡(株)製）（Ｗ3）のウエブ補集部に実施
例１で使用した強化支持体Ａ1およびＢ1をそれぞれ給送
し、層構成がＷ3/Ａ1およびＷ3/Ｂ1となるように重ね合
わせ、１００メッシュの金網を備えた処理水透過性のス
クリーンからなる無端ベルトコンベヤ上に給送し、上方
より、オリフィス径０.１５ｍｍ、ピッチ１.０ｍｍで多
数の小径ノズルを備えた３列のノズル列を通して、第１
列７０kg/cm2、第２列９０kg/cm2および第３列１１０kg
/cm2の圧力で高圧水流を噴射しながら１００m/min の速
度で表側から１回、裏側から更に１回絡合処理を行った
後、乾燥して薄手軽量強化水流絡合不織布を得た。比較
例３として、本実施例に使用したポリウレタン系ストレ
ッチ性メルトブローン不織布（Ｗ3）のみを用い、同じ
条件で水流絡合処理を行った。これらの物性を表３に示
す。
【００２４】
【表３】
【００２５】＜実施例４、比較例４＞繊度２デニール、
長さ５０ｍｍおよび平均坪量２５g/m2のナイロン短繊維
をカード・パラレル方式により二次元配列してウエブ層
（Ｗ4）とした。ポリプロピレン樹脂を原料として実施
例２と同様にして縦延伸一方向配列長繊維不織布
（Ａ2）および横延伸一方向配列長繊維不織布（Ｂ2）を
得た。不織布Ａ2および不織布Ｂ2を経緯直交させて積層
し、ポリビニルアルコールによる仮接着を行い坪量１３
g/m2の延伸交差積層不織布（Ｃ4）を得た。また、不織
布Ａ2および不織布Ｂ2を経緯直交させて積層し、熱エン
ボス加工を行い坪量１２g/m2の延伸交差積層不織布（Ｄ
4）を得た。これらの不織布を強化支持体として使用し
た。ウエブ層と強化支持体との層構成がＣ4/Ｗ4/Ｃ4お
よびＤ4/Ｗ4/Ｄ4となるように重ね合わせ、１００メッ
シュの金網を備えた処理水透過性のスクリーンからなる
無端ベルトコンベヤ上に給送し、上方より、オリフィス
径０.１５ｍｍ、ピッチ１.０ｍｍで多数の小径ノズルを
備えた３列のノズル列を通して、第１列７０kg/cm2、第
２列９０kg/cm2および第３列１１０kg/cm2の圧力で高圧
水流を噴射しながら１００m/min の速度で表側から１
回、裏側から更に１回絡合処理を行った後、乾燥して薄
手軽量強化水流絡合不織布を得た。比較例４として、本
実施例とほぼ同じ坪量のナイロン短繊維ウエブ（Ｗ4）
のみを用い、同じ条件で水流絡合処理を行った。これら
の物性を表４に示す。
【００２６】
【表４】
【００２７】
【発明の効果】本発明によって得られた薄手軽量強化水
流絡合不織布は、引張強度、剥離強度、ソフトな風合
い、ドレープ性、地合等に優れており、かつ縦横の強度
バランスを用途特性に合わせ自由に設計することがで
き、ウエブ形成工程や水流絡合工程が本来有している高
速生産性を損なうことがなく経済的であり、補強機能や
伸縮方向規制機能等を生かした芯地等の衣料製品、フィ
ルターや工業用ワイパー等の産業用資材、および手術
衣、シーツ、タオル、マスク等のメディカルディスポー
ザブル製品等に広く用いられる。Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforced hydroentangled nonwoven fabric which is thin and lightweight, has a drapability and flexibility, and has an improved vertical and horizontal strength balance, and a web forming process. And a method for producing the above-mentioned nonwoven fabric, which does not reduce the high-speed productivity inherent in the water entanglement step. More specifically,
Related to thin and lightweight reinforced water-entangled nonwoven fabrics widely used for clothing products such as interlining, industrial materials such as filters and industrial wipers, and medical disposable products such as surgical gowns, sheets, towels and masks, and a method for producing the same. It is. [0002] By injecting high pressure fluid onto a short fiber web, the fibers forming the web are entangled with each other,
A method of giving a web an appropriate entangled structure and specific physical properties is widely practiced as a hydroentanglement method. Nonwoven fabrics manufactured by the hydroentanglement method have a greater degree of freedom for each fiber to move relative to each other than other nonwoven fabrics because there are no bonding points between the fibers, so they are rich in flexibility, lint-free, and drapeable. It has a soft texture. However, since the fibers are not bonded to each other, there is a disadvantage in that the strength is weak, unstable, and easily deformed. In addition, since the injection trace of the high-pressure fluid is continuously left in the vertical direction (flow direction) of the web, the strength balance in the vertical direction and the horizontal direction is poor. In order to improve the strength balance, a process such as a cross layer must be added. However, there is a drawback that it becomes necessary and becomes thicker than necessary, and the productivity is reduced. As a method of improving such a defect, a method of using a nonwoven fabric made of staple fibers as a reinforcing substrate (Japanese Patent Laid-Open No. 54-82481).
JP-A-54-101981, JP-A-54-101981, and a method using a reinforcing material composed of a woven fabric, a knitted fabric, or a non-woven fabric.
1-222561), a method using wood pulp as a reinforcing base material (Japanese Patent Application Laid-Open No. 59-94659), and a method of intertwining a short fiber web with a mesh material (Japanese Patent Application Laid-Open No. 1-32196).
No. 0, JP-A-4-263660), a method of intertwining a short fiber web with a spunbonded nonwoven fabric (JP-A-Hei.
-333652, JP-A-4-153351) and the like. [0003] However, in the improvement methods using a reinforced support disclosed in these disclosed techniques, the purpose of strengthening is achieved in any case, but the softness, which is a feature of the hydroentangled nonwoven fabric, is furthermore achieved. There is no known technique for producing a nonwoven fabric which is thin, lightweight and has an improved strength balance by a simple and economical method while maintaining the properties, lint-free properties, drapability and soft texture. In addition, when the web is subjected to a cross-layer treatment or the like for the purpose of improving the strength balance of the nonwoven fabric, the production speed of forming the web layer generally becomes 1 /
2 to 1/50, and the productivity of the subsequent hydroentanglement step is also reduced. Performing a similar treatment during or after hydroentanglement also reduces productivity. A technique for producing a nonwoven fabric having excellent strength balance without lowering the high-speed productivity inherent in the web layer forming step and the water entanglement step is also not known. The present inventors have conducted intensive studies to solve the above-mentioned problems, and as a result, have found that a specific base material has been applied to a web layer made of natural fibers, regenerated fibers or synthetic fibers. By injecting a high-pressure water stream onto the multilayer body superimposed as a reinforced support, the fibers are entangled with the reinforced support to improve the strength balance in the vertical and horizontal directions, and flexibility,
Lint-free, drape, soft texture, etc.Thin lightweight lightweight reinforced hydroentangled nonwoven fabric can be produced without reducing the high-speed productivity inherent in the web forming step and the hydroentanglement step. The present invention has been completed. That is, the first invention of the present application provides a reinforced support composed of a stretched cross-laminated nonwoven fabric in which a web layer in which natural fibers, regenerated fibers or synthetic fibers are arranged, and a long-fiber nonwoven fabric are laminated perpendicularly to each other, comprising the following steps. composed by integrating the body, a basis weight (g / m 2) per tensile strength (g / 3 cm width) is, longitudinal direction 1
The present invention provides a method for producing a thin, lightweight, reinforced water-entangled nonwoven fabric having 14 to 161, and a transverse direction of 102 to 169 . 1) a step of arranging natural fibers, regenerated fibers or synthetic fibers to produce a web layer; 2) giving a thermoplastic resin a hot-air swirling or vibration to the melt-spun filaments ejected from a spinneret while arranging them in the longitudinal direction. A process of producing a long-fiber nonwoven fabric in which almost all undrawn filaments are arranged in a longitudinal direction by accumulating on a belt conveyor, and 3) the long-fiber nonwoven fabric obtained in the step 2) is stretched by 5 to 12 in the longitudinal direction by close-to-roll stretching. A double-stretching process for producing a longitudinally stretched unidirectional long-fiber nonwoven fabric having an average fineness of 0.01 to 10 deniers; 4) a hot-air swirling or vibration is applied to a molten spun filament ejected from a spout from a thermoplastic resin; 5) a process of producing a long-fiber nonwoven fabric in which almost all undrawn filaments are arranged in the lateral direction by accumulating on a belt conveyor while being arranged in the lateral direction, and 5) obtained in step 4). A step of producing a transversely stretched unidirectionally aligned long-fiber nonwoven fabric in which the long-fiber nonwoven fabric is stretched 5 to 12 times in the transverse direction by a transverse stretching method and having an average fineness of 0.01 to 10 deniers; A reinforced support composed of a stretched cross-linked nonwoven fabric having a basis weight of 1 to 80 g / m 2 , obtained by laminating the vertically stretched unidirectionally aligned long-fiber nonwoven fabric obtained in step 5) and the transversely stretched unidirectionally aligned long-fiber nonwoven fabric obtained in step 5). 7) The web layer obtained in the step 1) and the reinforced support obtained in the step 6) are laminated and transported, and a high-pressure water stream of 10 to 300 kg / cm 2 is jetted while the layer is conveyed. A step of integrating the web layer and the reinforced support by performing entanglement at 2 to 200 m / min. Hereinafter, the present invention will be described in more detail. The web layer composed of natural fibers, regenerated fibers or synthetic fibers used in the present invention includes natural fibers such as cotton, linter and pulp, regenerated cellulose fibers such as rayon and cupra, semi-synthetic cellulose fibers such as acetate, polyethylene, polypropylene and polyester. , Polyamide, polyacrylonitrile, acrylic, synthetic fibers such as polyvinyl alcohol or polyurethane-based and polyester-based elastomer fibers, conjugate fibers, split-type composite fibers separated into ultra-fine fibers by high-pressure water flow, or any of them. The mixture was used as a raw material. To form a web layer, a method in which regenerated fibers or the like are wet-spun or synthetic fibers are melt-spun in a usual manner, cut, and the fibers are aligned on a card machine to form a web, or natural fibers are formed. For example, a method of forming a web by aligning with a card machine or making a web by beating is used. The fineness of the fibers in the web layer is preferably 0.01 to 15 denier, more preferably 0.03 to 5 denier.
Denier, the fiber length is preferably 1-100 m
m, more preferably 10 to 60 mm. If the single yarn fineness is less than 0.01 denier, the lint-free property is poor, and
If it exceeds denier, the texture is inferior. The length of the fiber is 1
If the diameter is less than 100 mm, the entanglement is insufficient and the strength is low.
If it exceeds, dispersibility deteriorates, which is not preferable. Further, the basis weight of the web is preferably 10 to 150 g / m 2 , more preferably 20 to 50 g / m 2 . When the grammage is less than 10 g / m 2 , the density of the fiber becomes uneven during high-pressure water flow treatment, and the
Since the inferior in thin lightweight exceeds m 2, both undesirable. [0007] The long fiber used in the present invention may be drawn in advance, but it is necessary that the secondary drawing can be performed twice or more. Various forms are used as the method for forming the long-fiber nonwoven fabric of the present invention, and the spinning filaments of the thermoplastic resin are arranged in the vertical or horizontal direction by applying a swirl or vibration with hot air so that almost all of the fibers are unidirectional. A method of forming an arrayed nonwoven fabric, a method of spinning a thermoplastic resin, drawing, opening, collecting and entanglement to form a nonwoven fabric (for example, a spunbond method), and injecting a thermoplastic resin with high-temperature and high-pressure air (Eg, melt blown method), a method of forming a nonwoven fabric by stretching and crimping a long fiber bundle of a thermoplastic resin, and performing opening and widening (eg, tow opening method). ), Foaming extrusion of a thermoplastic resin, foam rupture, lamination and spreading to form a nonwoven fabric (for example, a burst fiber method) and the like. In the present invention, as a reinforced support, a long-fiber nonwoven fabric spun from a thermoplastic resin is stretched in one direction, and a stretched unidirectionally-arranged nonwoven fabric in which long fibers are arranged in almost one direction, or a nonwoven fabric thereof. A stretched cross-laminated nonwoven fabric laminated so that the arrangement axes intersect is used. The stretching of the present invention includes a rolling process. As the stretching means, a longitudinal stretching means used for stretching a conventional film or nonwoven fabric,
Lateral stretching means and biaxial stretching means can be used. That is, as the longitudinal stretching means, the inter-roll proximity stretching is preferable because the stretching can be performed without reducing the width. In addition, roll rolling, hot air stretching, hot water stretching, steam stretching and the like can also be used. As horizontal stretching means,
A tenter method used for biaxial stretching of a film can also be used, but a pulley type lateral stretching method exemplified in the above-mentioned Japanese Patent Publication No. 3-36948 or a lateral stretching method combining groove rolls (a groove roll method) ) Is simple. As the biaxial stretching means, a tenter type simultaneous biaxial stretching method used for biaxial stretching of a film can be used, but it can also be achieved by combining the above-described longitudinal stretching means and transverse stretching means. The stretching ratio of the stretched unidirectionally aligned nonwoven fabric is 5 to 20 times, preferably 8 to 12 times. The average fineness of the stretched nonwoven fabric is from 0.01 to 10 denier, preferably from 0.03 to 5 denier.
The basis weight of the single-layer or laminated nonwoven fabric is 1 to 80 g / m 2 , preferably 5 to 30 g / m 2 . As the reinforced support in the present invention, a nonwoven fabric formed by stretching and arranging long fibers spun from a thermoplastic resin in the longitudinal direction, a nonwoven fabric formed by stretching and arranging the long fibers in the transverse direction, their arrangement Nonwoven fabrics laminated in the same axial direction, cross-laminated nonwoven fabrics thereof, and long fiber nonwoven fabrics biaxially stretched can be used. The thermoplastic resin used as a raw material of the long-fiber nonwoven fabric used in the present invention includes high density, medium density and low density polyethylene, linear low density polyethylene, ultra low density polyethylene, polypropylene and propylene-ethylene copolymer. Propylene polymers, α-olefin polymers, polyamides, polyesters, polycarbonates, polyvinyl alcohols, etc., of which polypropylene and polyester are particularly preferred. It is also possible to add an antioxidant, an ultraviolet absorber, a lubricant or the like to the resin before use. In the present invention, the combination of a web layer composed of a natural fiber, a recycled fiber or a synthetic fiber and a reinforced support is a two-layer structure in which a fiber web layer (A) and a reinforced support (B) are alternately stacked. The above can be used.
For example, arbitrary combinations such as A / B, A / B / A, B / A / B, and A / B / A / B are possible. Next, the method for producing the thin and lightweight reinforced water-entangled nonwoven fabric of the present invention will be described in detail. The manufacturing method is
(1) a web layer forming step, (2) a lamination supply step of supplying a web layer and a reinforced support while overlapping each other, (3) a high-pressure water entanglement step of performing a water jet treatment, (4) a drying step,
And (5) a product winding step. First, in the (1) web layer forming step, various types of web arrangement and forming methods are used depending on the type of raw material and the end use. As the characteristics of the web, it is required that the dispersion of the fibers is uniform and regular in all directions in the plane and in the thickness direction.・ Parallel method, semi-random method with semi-random machine of two-dimensional and three-dimensional intermediate arrangement, random method of blowing fibers by air blow and accumulating on mesh screen, spinning resin by dry or wet method, stretching, Examples include a spunbond method by a continuous web forming method of performing opening, collection and entanglement, and a wet web forming method in which natural fibers, regenerated fibers, and the like are beaten and made into paper. Although the production speed is somewhat reduced, a card cross-layer method using a mechanical cross-web forming method crosswise arranged in an oblique direction in order to obtain a strength balance in three directions may be used. FIG. 1 is a schematic diagram showing an example of the above-mentioned steps after (2) the lamination supply step. In the lamination supply step, the web layer 1 and the reinforced support 2 that have been wound up in advance are supplied to the respective supply rolls 1 a and 2
a. This is an off-machine method,
(1) An on-machine method in which a web layer and a reinforced support are overlapped (not shown) in the fiber collecting section in the web layer forming step according to the structure of the product, and are continuously fed to the subsequent high-pressure water entanglement step. It can also be manufactured. In the next (3) high-pressure water entanglement step, the fed web layer and the reinforced support are laminated on a screen or a roll as the transfer support 3 that is permeable or impermeable to treated water. A thin water stream 5 a is jetted from the high-pressure water stream small-diameter nozzle row 5 to the body 4. In addition, before injecting a water flow, the laminate is immersed in water 6a in a water immersion device 6 in advance.
It is preferable to remove water from the viewpoint of increasing the efficiency of the operation. In addition, in order to carry out the water entanglement effectively, it is desirable to apply the high pressure water entanglement from both sides of the web layer laminate. That is, the web layer laminate 4 that has left the first transfer support 3 is guided onto the second transfer support 3a, and a thin water flow 5c is jetted from the high-pressure water flow small-diameter nozzle array 5b. The high pressure water entanglement is performed from the surface opposite to the surface entangled by the water flow 5a. In the high-pressure water entanglement step, when the high-pressure water flow treatment is performed on a screen, the screen is not particularly limited. However, in order to facilitate the treatment of discharging the treated water, the material and mesh size are adjusted according to the purpose and application. , Wire diameter and the like are preferably selected. The mesh size is usually 20 to 200 mesh. In the method using the transfer support having permeability to the treated water, the treated water is easily discharged, so that it is possible to prevent the web from being scattered by the jet of the water flow and impairing the uniformity. However, the treated water once passed through the web still has considerable energy remaining, and is not high in energy efficiency. On the other hand, in the method using the transfer support which is impermeable to treated water, the jet water flow transmitted through the web collides with the transfer support and becomes a repulsive flow and acts again on the web. The entanglement is efficiently performed by the interaction. However, since the high-pressure water stream is jetted to the web floating in the water, there is a disadvantage that the stability of the entanglement is reduced. Among these, a method of performing a jetting treatment of a high-pressure water stream on a transfer support permeable to treated water is preferable. The jet stream is jetted from a small-diameter nozzle row arranged in a row at a pitch of 0.2 mm or more from a direction perpendicular to the transport direction. The orifice diameter of the small diameter nozzle is 1
mm or less, and preferably 0.1 to 0.5 mm. The jetted liquid is preferably water, and if necessary for hygiene, hot water or ultrapure water may be used. The pressure of the jet stream is 10-300
a kg / cm 2, preferably from 20 to 200 kg / cm 2.
If the pressure is less than 10 kg / cm 2 , the entanglement effect is insufficient, and if it exceeds 300 kg / cm 2 , the cost of the high-pressure water flow increases and the handling is difficult. Injection is performed at least once, but a method of arranging several small-diameter nozzle rows and increasing the injection water pressure in a stepwise manner is preferable. That is, the first stage entangles the surface layer at a low pressure, and while increasing the water pressure with the subsequent small-diameter nozzle row, advances the entanglement from the intermediate layer to the lower layer, thereby efficiently obtaining a non-disturbed hydroentangled nonwoven fabric. be able to. Further, depending on the material and shape of the web layer, the basis weight, the number of treatments, and the like, the low pressure method (20
~ 55 kg / cm 2 ), medium pressure method (55-90 kg / cm 2 ) and high pressure method (90-200 kg / cm 2 ). Although the shape of the high-pressure fluid is not particularly limited, a columnar flow is preferable from the viewpoint of energy efficiency. The cross-sectional shape of the columnar flow is determined by the cross-sectional shape or internal structure of the small-diameter nozzle, but can be freely selected depending on the material, purpose, application, and the like of the web. The processing speed of the hydroentanglement process is 2
~ 200m / min, preferably 50 ~ 150m / min
It is. When the processing speed is less than 2 m / min, the productivity is low, and when the processing speed is more than 200 m / min, the entanglement effect is insufficient. The laminate composed of the web layer and the reinforced support entangled by jetting a high-pressure water stream is subjected to (4) a drying step using, for example, an oven 8, a hot blast stove or a hot cylinder, and (5) product winding. In the process, it is wound up as a thin and lightweight reinforced water entangled nonwoven fabric 9. The thin and lightly reinforced water entangled nonwoven fabric of the present invention is a reinforced nonwoven fabric obtained by stretching a long-fiber nonwoven fabric in one direction and arranging fibers in substantially the same direction, or a nonwoven fabric obtained by cross-laminating them. Since it is reinforced by the support, it has high strength despite its thinness and light weight, which is an excellent advantage that cannot be achieved by the conventional hydroentangled nonwoven fabric. In addition, as the reinforcing support, it is possible to freely select a nonwoven fabric having a high strength only in the vertical direction, a nonwoven fabric having a high strength only in the horizontal direction, and a nonwoven fabric having an excellent strength balance in the vertical and horizontal directions, depending on the application. A strength balance can be imparted to the final product. As seen in many conventional nonwoven fabrics, it is possible to provide a product in which the vertical and horizontal strength balance is arbitrarily adjusted without causing any unreasonable vertical or horizontal strength balance or excessive vertical strength. The present invention will be described below with reference to examples. <Example 1, Comparative Example 1> Fineness 2 denier, length 50 mm
Rayon staple fibers having an average basis weight of 20 g / m 2 were two-dimensionally arranged by a card parallel method to form a web layer (W 1 ). Using a polyethylene terephthalate (PET) resin (trade name: MA 2100, manufactured by Unitika Ltd.) as a raw material, the molten spun filaments ejected from the spinneret are swirled by hot air to be arranged in the vertical direction, and the endless mesh endlessly circulates. The filament was accumulated on a belt conveyor to obtain a long-fiber nonwoven fabric in which undrawn filaments having a fineness of 2 deniers were arranged in the longitudinal direction.
Next, the nonwoven fabric is stretched 10 times in the longitudinal direction by roll-to-roll proximity stretching to a fineness of 0.2 denier, and is temporarily bonded with polyvinyl alcohol to obtain a longitudinally stretched unidirectional long-fiber nonwoven fabric having a basis weight of 8 g / m 2. (A 1 ) was obtained. In addition, the same resin is spun in the same manner to prepare a long-fiber nonwoven fabric arranged in the transverse direction, stretched 10 times in the transverse direction by a pulley type transverse stretching method to a fineness of 0.2 denier, and temporarily bonded with polyvinyl alcohol. Thus, a nonwoven fabric (B 1 ) having a basis weight of 8 g / m 2 and a transversely stretched unidirectionally aligned long fiber was obtained. The nonwoven fabric A 1 and nonwoven B 1 by history orthogonally stacked, stretched cross-laminated nonwoven fabric having a basis weight of 15 g / m 2 performs temporary adhesion by polyvinyl alcohol (C 1) was obtained. Further, the nonwoven fabric A 1 and nonwoven B 1 by history orthogonal laminated, to obtain a stretched cross-laminated nonwoven fabric having a basis weight of 14 g / m 2 by thermal embossing (D 1). These nonwovens were used as reinforced supports. Layer structure of the web layer and the reinforcing support is W 1 / A 1 / W 1 , W 1 / B 1 / W 1, W 1 / B 1 / B 1 / W 1, W 1 / C 1
/ W 1 and W 1 / D 1 / W 1 are superimposed so that 10
The nozzle is fed onto an endless belt conveyor consisting of a treated water permeable screen provided with a 0-mesh wire mesh, and from above, a nozzle row of 0.15 mm orifice diameter, 1.0 mm pitch, and a large number of small-diameter nozzle rows with many small-diameter nozzles Through the first row 70kg / c
m 2, the second column 90 kg / cm 2 and the third row once from the front side at a speed of 100 m / min while jetting high-pressure water jet at a pressure of 110 kg / cm 2, after further once entangling treatment from the back side And dried to obtain a thin and lightweight reinforced water entangled nonwoven fabric. As Comparative Example 1, a hydroentanglement treatment was performed under the same conditions using only a rayon short fiber web (W 1 ) having the same basis weight as in this example. Table 1 shows these physical properties. [Table 1] <Example 2, Comparative Example 2> Fineness 2 denier,
Polypropylene having a length of 50 mm and an average basis weight of 20 g / m 2 (trade name: Nisseki Polypro J120, Nippon Petrochemical Co., Ltd.)
) Were two-dimensionally arranged by a card parallel method to form a web layer (W 2 ). Polypropylene resin (density 0.90 g / cm 3 , melt flow rate 700 g / 10 mi
Using n) as a raw material, spinning was carried out in the same manner as in Example 1 to obtain a longitudinally arranged long-fiber nonwoven fabric composed of undrawn filaments having a fineness of 2 deniers. It was stretched to a fineness of 0.2 denier, and temporarily bonded with polyvinyl alcohol to obtain a longitudinally stretched unidirectional long-fiber nonwoven fabric (A 2 ) having a basis weight of 6 g / cm 2 . Further, a long-fiber nonwoven fabric arranged in the horizontal direction obtained from the above raw material in the same manner as in Example 1 was similarly stretched in the horizontal direction to a fineness of 0.2 denier, and temporarily bonded with polyvinyl alcohol to obtain a basis weight of 6 g / g. transverse stretching unidirectionally aligned long-fiber nonwoven fabric of cm 2 (B 2)
I got Non-woven fabric A 2 and non-woven fabric B 2 are laminated perpendicularly to each other, and temporarily bonded with polyvinyl alcohol to obtain a basis weight of 1.
A stretched cross-laminated nonwoven fabric (C 2 ) of 1 g / m 2 was obtained. Further, the nonwoven fabric A 2 and nonwoven B 2 by history orthogonal laminated, to obtain a stretched cross-laminated nonwoven fabric having a basis weight of 10 g / m 2 by thermal embossing (D 2). These nonwovens were used as reinforced supports. And feeding the reinforcing support collecting portion of the card parallel web forming step, a layer structure is W 2 / A 2 / W 2 , W 2 / B 2 /
W 2 , W 2 / B 2 / B 2 / W 2 , W 2 / C 2 / W 2 and W 2 / D 2 / W 2
And fed onto an endless belt conveyor consisting of a treated water permeable screen equipped with a 100 mesh wire mesh, and from above, an orifice diameter of 0.15 mm.
The first row is 70 kg / cm 2 , the second row is 90 kg / c through three nozzle rows with a number of small-diameter nozzles at a pitch of 1.0 mm.
m 2 and the third row, the entanglement treatment is performed once from the front side and once more from the back side at a speed of 100 m / min while jetting a high-pressure water stream at a pressure of 110 kg / cm 2 , and then dried to obtain a thin and lightweight reinforced water stream. An entangled nonwoven fabric was obtained. As Comparative Example 2, a hydroentanglement treatment was performed under the same conditions using only a polypropylene short fiber web (W 2 ) having the same basis weight as that of the present example. Table 2 shows these physical properties. [Table 2] <Example 3 and Comparative Example 3> Reinforcement used in Example 1 for the web collecting portion of a polyurethane-based stretch-blown meltblown nonwoven fabric (trade name: Espansione, manufactured by Kanebo Co., Ltd.) (W 3 ) Each of the supports A 1 and B 1 was fed and superposed so that the layer composition became W 3 / A 1 and W 3 / B 1, and an endless screen composed of a treated water permeable screen provided with a 100-mesh wire mesh. It is fed onto a belt conveyor, and from above, passes through three nozzle rows with a large number of small-diameter nozzles with an orifice diameter of 0.15 mm and a pitch of 1.0 mm.
Row 70 kg / cm 2 , second row 90 kg / cm 2 and third row 110 kg
The entanglement treatment was performed once from the front side and one more time from the back side at a speed of 100 m / min while spraying a high-pressure water stream at a pressure of / cm 2 , and then dried to obtain a thin and lightweight reinforced water entangled nonwoven fabric. As Comparative Example 3, only the polyurethane stretchable meltblown nonwoven fabric (W 3 ) used in this example was subjected to the hydroentanglement treatment under the same conditions. Table 3 shows these physical properties. [Table 3] <Example 4, Comparative Example 4> Fineness 2 denier,
Nylon short fibers having a length of 50 mm and an average basis weight of 25 g / m 2 were two-dimensionally arranged by a card parallel system to form a web layer (W 4 ). Using a polypropylene resin as a raw material, a longitudinally stretched unidirectionally aligned long fiber nonwoven fabric (A 2 ) and a laterally stretched unidirectionally aligned long fiber nonwoven fabric (B 2 ) were obtained in the same manner as in Example 2. Non-woven fabric A 2 and non-woven fabric B 2 are laminated perpendicularly to each other, and temporarily bonded with polyvinyl alcohol to obtain a basis weight of 13
A stretched cross-laminated nonwoven fabric (C 4 ) of g / m 2 was obtained. Further, the non-woven fabric A 2 and the non-woven fabric B 2 are laminated so as to be orthogonal to each other, and subjected to hot embossing to obtain a stretched cross-laminated non-woven fabric (D) having a basis weight of 12 g / m 2.
4 ) Got it. These nonwovens were used as reinforced supports. The web layer and the reinforced support are superposed so that the layer composition becomes C 4 / W 4 / C 4 and D 4 / W 4 / D 4, and the screen comprises a treated water permeable screen provided with a 100-mesh wire mesh. It is fed onto an endless belt conveyor, and is passed from above through three rows of nozzles having orifice diameters of 0.15 mm and pitches of 1.0 mm and having a large number of small-diameter nozzles. The first row is 70 kg / cm 2 , and the second row is 90 kg / cm 2 . cm 2 and the third row, from the front side at a speed of 100 m / min while injecting a high pressure water stream at a pressure of 110 kg / cm 2.
After performing the entanglement process once more from the back side, it was dried to obtain a thin and lightweight reinforced water entangled nonwoven fabric. As Comparative Example 4, a nylon short fiber web (W 4 ) having a basis weight almost the same as that of the present example.
The hydroentanglement treatment was performed under the same conditions using only the same. Table 4 shows these physical properties. [Table 4] The thin and lightweight reinforced water entangled nonwoven fabric obtained by the present invention is excellent in tensile strength, peel strength, soft texture, drape property, formation, etc., and has a good balance of strength in the vertical and horizontal directions. It can be freely designed according to the application characteristics, is economical without impairing the high-speed productivity inherent in the web forming process and the water entanglement process, and utilizes the reinforcing function and the function of regulating the expansion and contraction direction etc. It is widely used for clothing products such as interlining, industrial materials such as filters and industrial wipers, and medical disposable products such as surgical gowns, sheets, towels and masks.
【図面の簡単な説明】 【図１】本発明の製造工程の一例を示す概略図である。 【符号の説明】 １ ウエブ層 １ａ ウエブ層供給ロール ２ 強化支持体 ２ａ 強化支持体供給ロール ３、３ａ 移送用支持体 ４ 積層体 ５、５ｂ 高圧水流小径ノズル列 ５ａ、５ｃ 高圧水流 ６ 浸水装置 ６ａ 水 ７ 水分吸引装置 ８ オーブン ９ 薄手軽量強化水流絡合不織布[Brief description of the drawings] FIG. 1 is a schematic view showing one example of a production process of the present invention. [Explanation of symbols] 1 Web layer 1a Web layer supply roll 2 reinforced support 2a Reinforced support supply roll 3, 3a Transfer support 4 laminate 5, 5b High pressure water flow small diameter nozzle row 5a, 5c High pressure water flow 6 flooding equipment 6a water 7 Moisture suction device 8 oven 9 Thin and lightweight reinforced water entangled nonwoven fabric
───────────────────────────────────────────────────── フロントページの続き (58)調査した分野(Int.Cl.7，ＤＢ名) D04H 1/00 - 18/00 B32B 1/00 - 35/00 ──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. 7 , DB name) D04H 1/00-18/00 B32B 1/00-35/00
Claims (1)
維または合成繊維を配列したウェブ層と、長繊維不織布
を経緯直交させて積層した、延伸交差積層不織布からな
る強化支持体とを一体化させてなる、坪量（g/m2）当た
りの引張強度（g/3cm巾）が、縦方向が１１４〜１６
１、横方向が１０２〜１６９である薄手軽量強化水流絡
合不織布の製造方法。 １）天然繊維、再生繊維または合成繊維を配列してウェ
ブ層を製造する工程、 ２）熱可塑性樹脂を紡口より噴出した溶融紡糸フィラメ
ントに熱風で旋回または振動を与えて縦方向に配列させ
ながらベルトコンベア上に集積してほぼ全量の未延伸フ
ィラメントを縦方向に配列した長繊維不織布を製造する
工程、 ３）工程２）で得た長繊維不織布をロール間近接延伸に
より縦方向に５〜１２倍延伸し、平均繊度が０.０１か
ら１０デニールとした、縦延伸一方向配列長繊維不織布
を製造する工程、 ４）熱可塑性樹脂を紡口より噴出した溶融紡糸フィラメ
ントに熱風で旋回または振動を与えて横方向に配列させ
ながらベルトコンベア上に集積してほぼ全量の未延伸フ
ィラメントを横方向に配列した長繊維不織布を製造する
工程、 ５）工程４）で得た長繊維不織布を横延伸法により横方
向に５〜１２倍延伸し、平均繊度が０.０１から１０デ
ニールとした、横延伸一方向配列長繊維不織布を製造す
る工程、 ６）工程３）で得た縦延伸一方向配列長繊維不織布と工
程５）で得た横延伸一方向配列長繊維不織布を経緯直交
させて積層した坪量が１〜８０g/m2の延伸交差積層不織
布からなる強化支持体を製造する工程、 ７）工程１）で得たウェブ層と工程６）で得た強化支持
体とを積層して搬送しつつ、１０〜３００kg/cm2の高圧
水流を噴射して、処理速度２〜２００m/minで絡合加工
を施すことにより、該ウェブ層と該強化支持体とを一体
化する工程。(57) [Claims 1] A stretched cross-laminated nonwoven fabric comprising a web layer in which natural fibers, regenerated fibers or synthetic fibers are arranged, and a long-fiber nonwoven fabric laminated in a manner orthogonal to the process, comprising the following steps: made by integrating the reinforcing support comprising a basis weight (g / m 2) per tensile strength (g / 3 cm width) is the vertical direction 114-16
1. A method for producing a thin, lightweight, reinforced, water-entangled nonwoven fabric having a transverse direction of 102 to 169 . 1) a step of arranging natural fibers, regenerated fibers or synthetic fibers to produce a web layer; 2) giving a thermoplastic resin a hot-air swirling or vibration to the melt-spun filaments ejected from a spinneret while arranging them in the longitudinal direction. A process of producing a long-fiber nonwoven fabric in which almost all undrawn filaments are arranged in a longitudinal direction by accumulating on a belt conveyor, and 3) the long-fiber nonwoven fabric obtained in the step 2) is stretched by 5 to 12 in the longitudinal direction by close-to-roll stretching. A double-stretching process for producing a longitudinally stretched unidirectional long-fiber nonwoven fabric having an average fineness of 0.01 to 10 deniers; 4) a hot-air swirling or vibration is applied to a molten spun filament ejected from a spout from a thermoplastic resin; 5) a process of producing a long-fiber nonwoven fabric in which almost all undrawn filaments are arranged in the lateral direction by accumulating on a belt conveyor while being arranged in the lateral direction, and 5) obtained in step 4). A step of producing a transversely stretched unidirectionally aligned long-fiber nonwoven fabric in which the long-fiber nonwoven fabric is stretched 5 to 12 times in the transverse direction by a transverse stretching method and having an average fineness of 0.01 to 10 deniers; A reinforced support composed of a stretched cross-linked nonwoven fabric having a basis weight of 1 to 80 g / m 2 , obtained by laminating the vertically stretched unidirectionally aligned long-fiber nonwoven fabric obtained in step 5) and the transversely stretched unidirectionally aligned long-fiber nonwoven fabric obtained in step 5). 7) The web layer obtained in the step 1) and the reinforced support obtained in the step 6) are laminated and transported, and a high-pressure water stream of 10 to 300 kg / cm 2 is jetted while the layer is conveyed. A step of integrating the web layer and the reinforced support by performing entanglement at 2 to 200 m / min.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26844794A JP3464544B2 (en) | 1994-10-05 | 1994-10-05 | Method for producing thin and lightweight reinforced hydroentangled nonwoven fabric |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26844794A JP3464544B2 (en) | 1994-10-05 | 1994-10-05 | Method for producing thin and lightweight reinforced hydroentangled nonwoven fabric |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH08109563A JPH08109563A (en) | 1996-04-30 |
| JP3464544B2 true JP3464544B2 (en) | 2003-11-10 |
Family
ID=17458641
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP26844794A Expired - Fee Related JP3464544B2 (en) | 1994-10-05 | 1994-10-05 | Method for producing thin and lightweight reinforced hydroentangled nonwoven fabric |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3464544B2 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3545857B2 (en) * | 1995-11-06 | 2004-07-21 | 日本バイリーン株式会社 | Insulating composite and manufacturing method thereof |
| JP3657700B2 (en) * | 1996-06-18 | 2005-06-08 | 新日本石油化学株式会社 | Method for producing high-quality nonwoven fabric |
| JP2011184832A (en) * | 2010-03-10 | 2011-09-22 | Asahi Kasei Fibers Corp | Filter material for fuel suction filter |
| JP6084363B2 (en) * | 2012-03-06 | 2017-02-22 | ユニチカ株式会社 | Laminated nonwoven fabric and method for producing the same |
-
1994
- 1994-10-05 JP JP26844794A patent/JP3464544B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH08109563A (en) | 1996-04-30 |
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