JP2009280934A - Interior sheet and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an interior sheet giving warm and soft feeling and usable as interior materials in a room such as a window shade and wallpaper. <P>SOLUTION: The interior sheet is a laminate of a staple fiber nonwoven web and a spun-bonded nonwoven fabric, wherein the spun-bonded nonwoven fabric keeps its shape by depositing a number of thermoplastic synthetic fibers and partially hot-bonding the fibers and has a fabric weight of 15-35 g/m<SP>2</SP>, and the staple fiber nonwoven web has a fabric weight of ≥25 g/m<SP>2</SP>, includes cellulosic staple fiber as main fiber, and includes thermal binder staple fiber in an amount of 20-40 mass% in the staple fiber nonwoven web. The fibers constituting the staple fiber nonwoven web are three-dimensionally interlocked with each other and the staple fibers are interlocked with the thermoplastic synthetic fiber constituting the spun-bonded nonwoven fabric, the constitution fibers are thermally bonded by the melting or softening of the binder component of the thermal binder fiber, and the side of the staple fiber nonwoven web is used as the front surface. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an interior sheet used for indoor interior materials such as blinds and wallpaper.

Many blinds installed in windows are processed from gold and plastic, and in recent years, it has been required to use warm materials from the viewpoint of overall harmony with interior decorations, and textile products such as woven and non-woven fabrics. Has been proposed (Patent Document 1).
Japanese Patent Application Laid-Open No. 7-48779

  An object of the present invention is to provide an interior sheet that is a material that can feel warmth and softness, and is used for interior materials such as blinds and wallpaper.

The present invention is a sheet formed by laminating a short fiber nonwoven web and a spunbond nonwoven fabric, and the spunbond nonwoven fabric retains its form by depositing a large number of thermoplastic synthetic fibers and partially thermocompression bonding. In addition, the basis weight is 15 to 35 g / m ² , the short fiber nonwoven web has a basis weight of 25 g / m ² or more, cellulosic short fibers are the main fibers, and thermal binder short fibers are in the short fiber nonwoven web. The fibers constituting the short fiber nonwoven web are three-dimensionally entangled with each other, and the short fibers are entangled with the thermoplastic synthetic fiber constituting the spunbond nonwoven fabric, and the binder component of the thermal binder fiber is included. The gist of the interior sheet is that the constituent fibers are thermally bonded to each other by melting or softening, and the short fiber nonwoven web side is used as the surface side.

In addition, the present invention has a structure in which a number of thermoplastic synthetic fibers are deposited and partially thermocompression-bonded to maintain the form, and the basis weight is 15 to 35 g / m ^2. A short fiber nonwoven web comprising m ² or more and comprising cellulose-based short fibers as a main fiber and thermal binder short fibers in a short fiber nonwoven web of 20 to 40% by mass is laminated, and then the short fiber nonwoven web side Applying high-pressure water flow, the fibers constituting the short fiber nonwoven web are entangled three-dimensionally, and the short fibers are entangled and integrated with the thermoplastic synthetic fiber constituting the spunbonded nonwoven fabric, and then heated to smooth Pass the heated smooth roll through a thermal calender device consisting of a roll and an unheated smooth roll so that the heated smooth roll is located on the spunbond nonwoven fabric side, The gist is a method for producing an interior sheet characterized by softening.

  Hereinafter, the present invention will be described in detail.

  The interior sheet of the present invention is a sheet formed by laminating a short fiber nonwoven web and a spunbond nonwoven fabric, and uses the short fiber nonwoven web side as a surface side.

  A spunbonded nonwoven fabric is formed by depositing a large number of thermoplastic synthetic fibers, and maintains its form by being partially thermocompression bonded. Examples of the thermoplastic synthetic fiber constituting the spunbonded nonwoven fabric include fibers made of a polyester polymer, a polyamide polymer, a polyolefin polymer, and the like. Examples of the form of the fiber include a single-phase type composed of one kind of polymer and a composite type composed of two kinds of polymers. When the back surface side of the interior sheet is composed of the spunbonded nonwoven fabric, the dimensional stability and the shape stability are improved. This is because the spunbonded nonwoven fabric is composed of continuous fibers and partially thermocompression-bonded to maintain the shape, so it has excellent mechanical strength, is difficult to deform, and has good dimensional stability. Because.

Basis weight of the spunbonded nonwoven fabric is 15 to 35 g / m ^2. By being 15 g / m ² or more, the above-described mechanical strength, deformation resistance, and dimensional stability can be favorably taken. By setting it to 35 g / m ² or less, since the inter-fiber gap can be sufficiently retained in the non-compression bonding portion (the portion where the fibers are simply deposited) other than the thermocompression bonding portion, the heat constituting the spunbonded nonwoven fabric Short fibers can be satisfactorily entangled with the plastic synthetic fiber, and the spunbond nonwoven fabric and the short fiber nonwoven web are laminated and integrated well. In addition, 1-10 dtex is good for the single yarn fineness of the thermoplastic synthetic fiber which comprises a spun bond nonwoven fabric.

The crimping point density of the thermocompression bonding part in the spunbonded nonwoven fabric is preferably 50 to 70 / cm ² . By setting it to 50 pieces / cm ² or more, the spunbonded nonwoven fabric can bear good shape stability and dimensional stability in the sheet. In addition, because of the lamination and integration with the short fiber nonwoven web, the arrangement of the fibers existing between the thermocompression bonding parts is hardly disturbed by the action of the high-pressure water flow in the entanglement process, the dimensional stability is good, and the texture is good Sheet can be obtained. On the other hand, by setting the crimping point density to 70 cm ² or less, the region of the non-crimped part between the thermocompression-bonded parts can be appropriately held, and the constituent fibers of the short fiber nonwoven web constitute the spunbond nonwoven fabric. Can be entangled well with the thermoplastic synthetic fiber. The thermocompression bonding portion in the spunbonded nonwoven fabric may be any one that has been subjected to hot embossing.

The short fiber nonwoven web has a basis weight of 25 g / m ² or more, and the constituent fibers are entangled three-dimensionally. The basis weight of the short fiber nonwoven web is 25 g / m ² or more and the constituent fibers are three-dimensionally entangled and integrated, and the binder component of the thermal binder short fiber described later is melted or softened. In the interior sheet that is used with the short fiber nonwoven web side located on the surface, it has moderate elasticity in the thickness direction and is flexible and textured. It will be good. The compression recovery rate (RC), which is an index having elasticity in the thickness direction, is 60% or more on the short fiber nonwoven web side. The compression recovery rate is measured using a compression tester (model number: KES-FB3) manufactured by Kato Tech Co., and can represent the resilience after compression, that is, the sag of the sheet surface. When the compression recovery rate is 60% or more, the gaps in the sheet are retained even after compression, and the flexibility and texture are retained with difficulty in sagging.

  The short fiber nonwoven web contains cellulosic short fibers as main fibers and contains 20-40% by mass of thermal binder fibers in the short fiber nonwoven web. Examples of the cellulose short fibers include regenerated cellulose, rayon, lyocell, and cotton. In the present invention, cotton fibers are preferred because they are easily entangled with the spunbonded nonwoven fabric. The thermal binder short fiber contained in the short fiber nonwoven web serves to bond the constituent fibers to each other by melting or softening the binder component constituting the thermal binder short fiber when heat is applied. A single-phase type (total melting type) consisting only of a binder component or a composite type in which a binder component and a polymer having a higher melting point than the binder component are combined may be used. 20-40 mass% of thermal binder fibers are contained in the short fiber nonwoven web. By setting it as this range, while carrying the function which heat-bonds constituent fibers favorably and can hold | maintain the entanglement form of constituent fibers, the texture and flexibility of the sheet | seat obtained can be hold | maintained.

  The interior sheet of the present invention is formed by laminating a short fiber nonwoven web and a spunbond nonwoven fabric, and the fibers constituting the short fiber nonwoven web are three-dimensionally entangled and the short fibers constitute a spunbond nonwoven fabric. The constituent fibers are entangled with each other, and the constituent fibers are thermally bonded to each other by melting or softening the binder component of the thermal binder short fibers. Since the short fiber nonwoven web and the spunbond nonwoven fabric are integrated by the entanglement of the short fibers with the spunbond nonwoven fabric, the flexibility of the sheet surface is maintained. Moreover, since the binder component of the thermal binder fiber contained in the short fiber nonwoven web is melted or softened, the constituent fibers are thermally bonded to each other. A laminated sheet is obtained.

  The interior sheet of the present invention can be obtained by the following method.

  First, a short fiber nonwoven web and a spunbond nonwoven fabric are prepared. The short fiber nonwoven web is prepared by mixing a predetermined amount of cellulosic short fibers and thermal binder short fibers and passing the card through a card machine to prepare a web having a predetermined basis weight. A spunbond nonwoven fabric is prepared by depositing a large number of thermoplastic synthetic fibers and partially thermocompression bonding. The shape of the thermocompression bonding part in the spunbonded nonwoven fabric is not particularly limited, and may be an appropriate one such as a circle, a rhombus, or an ellipse. Moreover, although the crimping | compression-bonding point density of a crimping | compression-bonding part is as above-mentioned, 30-40% of the area ratio of a crimping | compression-bonding part is good.

  Next, a short fiber nonwoven web is laminated on the spunbonded nonwoven fabric, and the laminated web is supported on a mesh-like support. At this time, the spunbonded nonwoven fabric is on the support side. Any mesh support may be employed depending on the use of the interior sheet. When a mesh-like support made of a fine woven fabric of 80 to 100 mesh is used, a relatively smooth surface can be obtained. In addition, a mesh here refers to the sum of the line per inch, for example, the fabric of 100 mesh points out that 100 lines per inch exist.

  Next, a high-pressure water flow is applied to the laminated web, and the constituent fibers of the short fiber nonwoven web are entangled three-dimensionally, and the constituent fibers of the short fiber nonwoven web are infiltrated into the spunbonded nonwoven fabric to make thermoplastic synthetic fibers. Entanglement and unite. This high-pressure water flow uses an injection device in which injection holes having a hole diameter of 0.05 to 2.0 mm are arranged in one or more rows with an injection hole interval of 0.05 to 10 mm. It is obtained by jetting at a pressure of 40 MPa. By this kinetic energy, the constituent fibers of the short fiber nonwoven web are entangled with each other and entangled with the spunbond nonwoven fabric.

  Next, the moisture in the laminated and integrated sheet is removed through a drying process. Next, the obtained sheet is passed through a thermal calendar device. The thermal calender device heats one smooth roll, the other smooth roll is in an unheated state (room temperature), and passes the heated roll in contact with the spunbond nonwoven fabric side. The heat of the spunbond nonwoven fabric side heat roll is transmitted through the spunbond nonwoven fabric to the thermal binder short fibers entangled with the spunbond nonwoven fabric or present in the short fiber nonwoven web, and the binder component is melted or softened. The constituent fibers are thermally bonded. Here, by not directly contacting the heat roll on the short fiber nonwoven web side, the fibers can be thermally bonded and fixed while maintaining the bulkiness due to the three-dimensional entanglement, and in the thickness direction A sheet having moderate elasticity, good texture and flexibility can be obtained. Moreover, it is preferable to provide a clearance between the rolls in the thermal calendar device. Also by providing a clearance, a sheet having moderate elasticity, good texture and flexibility in the thickness direction can be obtained. The clearance between the rolls depends on the basis weight and thickness of the sheet to be processed, but it is preferable to provide a clearance of about 20% with respect to the thickness of the sheet to be processed (measured with a load of 2 kPa according to JIS L 1906).

  The interior sheet of the present invention is preferably used as wallpaper. By using the short fiber nonwoven web side so as to be positioned on the surface, the surface becomes a wallpaper having an appropriate cushioning property.

  The interior sheet of the present invention may be used as a blind installed in a room partition sheet or a window. By using the short fiber nonwoven web side as the surface, a soft impression is exhibited, and since the spunbond nonwoven fabric forms the back surface, the dimensional stability is excellent.

  In addition, the interior sheet of the present invention may be subjected to a printing process on the surface or a thermoforming process according to the application as long as the characteristics of the material are not impaired.

  The interior sheet of the present invention is obtained by laminating and integrating a short fiber nonwoven web and a spunbonded nonwoven fabric by short fibers entangled with the spunbonded nonwoven fabric. It is used so that the short fiber nonwoven web side is located on the surface, the surface has moderate elasticity, good texture, flexibility, and the spunbond nonwoven fabric on the back side bears dimensional stability and mechanical strength, Although the sheet is excellent in form stability, it is possible to provide an interior sheet having a soft impression on the surface.

  EXAMPLES Hereinafter, although this invention is demonstrated based on an Example, this invention is not limited to an Example. In addition, the various physical-property values of an Example and a comparative example were measured with the following method.

(1) Weight per unit area (g / m ² ): JIS L 1906 Mass per unit area

(2) Thickness (mm): JIS L 1906 Thickness Load measured at 2 kPa

(3) Compression recovery rate (%): The compression recovery rate (RC) was measured in a standard measurement state using a compression tester (model number: KES-FB3) manufactured by Kato Tech.

Example 1
Prepare cotton fibers (average fiber length: 25 mm) as cellulose-based short fibers and polyester-core-sheath composite short fibers (Unitika Fibers <4080>, fineness 2.2 decitex, fiber length 38 mm) as thermal binder short fibers. Cotton fiber and thermal binder short fiber were mixed as 70/30 (mass ratio) to produce a card web (short fiber nonwoven web) having a basis weight of 35 g / m ² .

On the other hand, as a spunbonded nonwoven fabric, it is partially thermocompression-bonded consisting of polyethylene terephthalate fiber (melting point 265 ° C., single yarn fineness 3.2 dtex) and copolymer polyester fiber (melting point 230 ° C., single yarn fineness 2.75 dtex). Spunbond nonwoven fabric (Marix (R) <70250WSO> manufactured by Unitika, unit weight 25 g / m ² , crimping point density of crimping part 64 pieces / cm ² , crimping part area ratio 16.2%) was prepared.

  On the 100 mesh conveyor net, the spunbond nonwoven fabric / short fiber nonwoven web is laminated and placed in this order from the net side, and after a pre-wet process, the nozzle hole diameter is 0.1 mm from the short fiber nonwoven web side. Using a spray device in which the spray holes were arranged in a horizontal row with a 0.6 mm hole interval, a high-pressure water flow was applied three times at a pressure of 6.9 MPa, and then a sheet was obtained through a drying process.

  Next, the obtained sheet (thickness 0.52 mm) was passed through a thermal calendar apparatus. In the thermal calendering apparatus, the surface temperature of one smooth roll was 125 ° C., the other smooth roll was not heated, and the room temperature was 0.1 mm. The spunbond nonwoven fabric was passed through the heat roll so as to be in contact with the heating roll, and heat treatment was performed to obtain the interior sheet of the present invention.

Example 2
In Example 1, the basis weight of the short fiber nonwoven web was set to 30 g / m ^2, and the spunbond nonwoven fabric had a basis weight of 30 g / m ² (Marix (R) <70300 WSO> manufactured by Unitika; An interior sheet was obtained in the same manner as in Example 1 except that the number of pieces / cm ² and the area ratio of the crimping part was 16.2%.

Comparative Example 1
In Example 1, the basis weight of the short-fiber nonwoven web was 20 g / m ^2, and the spunbond nonwoven fabric had a basis weight of 40 g / m ² (Marix (R) <70400 WSO> manufactured by Unitika, crimp point density 64) An interior sheet was obtained in the same manner as in Example 1 except that the number of pieces / cm ² and the area ratio of the crimping part was 16.2%.

Comparative Example 2
In Example 1, the sheet that was not subjected to the thermal calendar process was used as the sheet of Comparative Example 2.

Comparative Example 3
In Example 1, an interior sheet was obtained in the same manner as in Example 1 except that the mixing ratio of cotton fibers and thermal binder short fibers was 50/50 (mass ratio) as a short fiber nonwoven web.

Each of the interior sheets of Examples 1 and 2 was a sheet having excellent texture and good elasticity. On the other hand, each of the sheets of Comparative Examples 1 to 3 was a sheet with a small compression recovery rate and inferior non-existence.

Claims (8)

A sheet formed by laminating a short-fiber nonwoven web and a spunbonded nonwoven fabric. The spunbonded nonwoven fabric retains its shape by being deposited with a number of thermoplastic synthetic fibers and partially thermocompression-bonded. 15 to 35 g / m ² , the short fiber nonwoven web has a basis weight of 25 g / m ² or more, cellulosic short fibers as main fibers, and thermal binder short fibers as 20 to 40 in the short fiber nonwoven web. The fibers constituting the short fiber non-woven web are entangled three-dimensionally, and the short fibers are entangled with the thermoplastic synthetic fiber constituting the spunbond nonwoven fabric, and the binder component of the thermal binder fiber is melted or softened. The interior sheet is characterized in that the constituent fibers are thermally bonded to each other, and the short fiber nonwoven web side is used as the surface side. The interior sheet according to claim 1, wherein the cellulose-based short fibers which are main fibers of the short-fiber nonwoven web are cotton fibers. Claim 1 or 2 interior sheet according crimping point density of the thermocompression bonded portions that are partially thermocompression bonding the spunbonded nonwoven fabric is characterized in that it is a 50 to 70 / cm ^2. An interior sheet having a compression recovery rate of 60% or more on the short fiber nonwoven web side. The wallpaper comprised by the interior sheet of any one of Claims 1-4. The blind comprised by the interior sheet of any one of Claims 1-4. Form by a number of thermoplastic synthetic fibers is deposited partially thermocompression bonding is retained, and basis weight on one side of the spunbonded nonwoven fabric of 15 to 35 g / m ^2, the basis weight is not less 25 g / m ² or more cellulose A short fiber non-woven web containing 20 to 40% by mass of a short fiber as a main fiber and containing a thermal binder short fiber in the short fiber non-woven web, and then applying a high-pressure water flow from the short fiber non-woven web side. The fibers constituting the short fiber nonwoven web are entangled three-dimensionally, and the short fibers are entangled and integrated with the thermoplastic synthetic fiber constituting the spunbonded nonwoven fabric, and then the heated smooth roll and non-heated smooth It is passed through a heat calender device consisting of rolls so that the heated smooth roll is positioned on the spunbond nonwoven fabric side, and the thermal binder component of the thermal binder fiber is melted or softened. A method for producing an interior sheet that is characterized. The method for producing an interior sheet according to claim 7, wherein a clearance between the rolls is provided when the sheet is passed through a thermal calendar device.