JP2019189962A - Sheet-like article, and method of manufacturing the same - Google Patents

Abstract

To provide a sheet-like article having an even surface with an uncertain direction of piloerection since an ultra fine fiber composing a piloerection layer has crimp, and a method of manufacturing the same.SOLUTION: The sheet-like article composed of an ultra fine fiber having an average single fiber diameter of 0.1 μm or more and 10 μm or less, and an elastomer polymer includes: a base material layer; and a piloerection layer, where the ultra fine fiber composing the piloerection layer has crimp, the length of a piloerection length of the piloerection layer is 200 μm or more and 500 μm or less, and the rate of piloerection length change of an average length of a piloerection length when brushing the ultra fine fiber of the piloerection layer in a direction of piloerection to an average length of a piloerection length when brushing in a 180° direction to the direction of piloerection of the ultra fine fiber of the piloerection layer is 0% or more and 35% or less.SELECTED DRAWING: None

Description

  The present invention relates to a sheet-like product having a deformed appearance having a uniform surface quality, in which the direction of napping is unclear, and a manufacturing method thereof.

  Sheet-like materials composed mainly of ultrafine fibers having a mean single fiber diameter of 0.1 μm or more and 10 μm or less and a polymer elastic body have excellent characteristics not found in natural leather and are used as wall materials and interior materials. . Among them, a sheet-like material having an unusual appearance that hardly exhibits a lighting effect can be expected to show a different aspect from the above-mentioned sheet-like material as a wall material or an interior material.

  In order to obtain a sheet-like material having such an irregular appearance, studies have been made to use, for example, a side-by-side type composite fiber as a fiber constituting the sheet-like material.

  For example, Patent Document 1 proposes an artificial leather including a latent crimp-expressing fiber obtained by composite spinning of two types of polytrimethylene terephthalate having different intrinsic viscosities in a side-by-side manner.

  In Patent Document 2, a nonwoven fabric composed of side-by-side ultrafine fibers formed from two types of polyethylene terephthalate having different intrinsic viscosities in order to impart heat retention to a sheet-like material, and a water-dispersed polyurethane inside There has been proposed a sheet-like material containing.

  Furthermore, Patent Document 3 proposes a sheet-like material having, as a base material layer, a non-woven fabric made of side-by-side ultrafine fibers formed from two types of polyethylene terephthalate having different intrinsic viscosities.

  On the other hand, Patent Document 4 proposes to use, as a wiping sheet material, a non-woven fabric made of side-by-side ultrafine fibers formed from two types of polyethylene terephthalate having different intrinsic viscosities.

JP 2003-286663 A JP 2012-136800 A International Publication No. 2017/164162 JP-A-2018-16907

  However, when a side-by-side type composite fiber is used for the sheet-like material, it has been found difficult to obtain a sheet-like material with a deformed appearance in which the napping direction of the napped portion is unclear and has a uniform surface quality. It was.

  For example, in the technique disclosed in Patent Document 1, when the fiber length of the napped portion is short, the entanglement between the ultra fine fibers of the napped portion and the crimp of the ultra fine fiber are reduced, so that the direction of napped is clear It becomes. Or in the technique disclosed by patent document 4, since the napped layer which consists of ultrafine fibers shall be 200 micrometers or less, a base material layer may partly be exposed.

  On the other hand, in the technique disclosed in Patent Document 2, when the napped length is long, the appearance may be rugged and the quality may be deteriorated.

  Furthermore, in the technique disclosed in Patent Document 3, since the sheet-like material has stretch properties, there is a characteristic that the direction of napping is clarified by the movement during expansion and contraction.

  An object of the present invention is to provide a sheet-like article having an irregular appearance with an unclear orientation and a uniform surface quality, and a method for producing the same, in view of the actual state of the prior art.

  As a result of intensive studies to achieve the above-mentioned object, the present inventors have determined the average length of the napped lengths during brushing in the napping direction and in the opposite direction by setting the fiber length of the napped layer to a specific range. The present inventors have found that the difference in thickness can be suppressed and the appearance quality of the sheet can be improved.

  The present invention has been completed based on these findings, and according to the present invention, the following inventions are provided.

  The present invention is a sheet-like material composed of ultrafine fibers having an average single fiber diameter of 0.1 μm or more and 10 μm or less and an elastic polymer, wherein the sheet-like material comprises a base material layer and a napped layer, The nap length when the nap fibers of the nap have crimps, the nap length of the nap layer is not less than 200 μm and not more than 500 μm, and brushing in the napping direction with respect to the ultra fibers of the nap layer The average length of the napped length when brushed in the direction of 180 ° with respect to the average length of the napped and the napped direction of the ultrafine fiber of the napped layer is 0% or more and 35% or less. It is a sheet.

  According to a preferred aspect of the sheet-like material of the present invention, the ultrafine fibers constituting the sheet-like material are bimetal yarns in which polyesters having different intrinsic viscosities are bonded in a side-by-side manner in the fiber length direction.

Moreover, this invention is a method of manufacturing the above-mentioned sheet-like material, Comprising: It is a manufacturing method of a sheet-like material which performs the process of following (1) and (2) in this order.
(1) A raising step of forming a raised layer by subjecting a nonwoven fabric composed of ultrafine fibers only from the same direction to obtain a nonwoven fabric after the raising treatment (2) 110 ° C. or more and 150 ° C. or less of the nonwoven fabric after the raising treatment A step of expressing crimps in the ultrafine fibers of the raised layer by performing a heat treatment at a temperature of According to a preferred embodiment of the method for producing a sheet-like product of the present invention, the ultrafine fibers are polyesters having different intrinsic viscosity differences. It is a bimetallic yarn bonded in a side-by-side manner in the fiber length direction, and is obtained from a non-woven fabric composed of ultrafine fiber-expressing fibers.

  According to the sheet-like material of the present invention and the manufacturing method thereof, not only properties such as bulkiness and stretchability, but also a highly uniform sheet shape with high uniformity that no trace remains regardless of the brushing direction. You can get things.

FIG. 1 is a conceptual perspective view illustrating a method for evaluating the surface quality of a sheet-like material according to the present invention.

  The sheet-like material of the present invention is a sheet-like material composed of an ultrafine fiber having an average single fiber diameter of 0.1 μm or more and 10 μm or less and an elastic polymer, and the sheet-like material comprises a base material layer and a napped layer. The ultrafine fibers constituting the raised layer have crimps, the length of the raised layer of the raised layer is not less than 200 μm and not more than 500 μm, and the brushed brush is brushed in the raised direction with respect to the ultrafine fiber of the raised layer With respect to the average length of the napped length and the direction of napping of the ultrafine fibers of the raised layer, the rate of change of the napped length when brushed in the direction of 180 ° is 0% or more and 35% or less. It is a sheet-like thing characterized by this. According to a preferred aspect of the sheet-like material of the present invention, the ultrafine fibers constituting the sheet-like material are bimetallic yarns in which polyesters having different intrinsic viscosities are bonded in a side-by-side manner in the fiber length direction. These are described in detail below.

[Ultra fine fiber]
Examples of the polymer forming the ultrafine fiber used in the present invention include polyesters such as polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate and polylactic acid, polyamides such as 6-nylon and 66-nylon, acrylic, polyethylene, and polypropylene. And thermoplastic resins that can be melt-spun such as thermoplastic cellulose. Of these, polyester fibers made of a polyester polymer such as polyethylene terephthalate, polybutylene terephthalate, and polytrimethylene terephthalate are preferably used from the viewpoints of strength, dimensional stability, light resistance, and dyeability. In addition, at least 2 or more types selected from these polymers may be combined. Moreover, the fiber obtained from a recycling raw material or a plant-derived raw material from a viewpoint of environmental consideration may be sufficient. Further, the ultrafine fibers can be configured by mixing fibers of different materials. In addition, the polymer constituting the ultrafine fiber may be copolymerized with other components, and may contain additives such as organic particles, inorganic particles, flame retardants, and antistatic agents.

  The ultrafine fiber constituting the sheet-like product of the present invention is a composite fiber in which two different types of polymers (A) and (B) are bonded side by side along the fiber length direction. The combination of the polymer (A) and the polymer (B) can be appropriately selected from the polymers forming the ultrafine fibers, but is preferably a combination of polyester polymers having a difference in intrinsic viscosity, more preferably At least one of the polymer (A) or the polymer (B) is a polybutylene terephthalate polymer. In particular, the ultrafine fiber obtained by spinning and stretching so as to form a structure in which a polymer of such a combination is bonded to the side-by-side type along the fiber length direction has two components due to stress concentration on the high viscosity side during stretching. Different internal strains occur between them, and heat treatment after forming into a sheet thereby causes the high-viscosity side to shrink significantly, producing strain within the single fiber and developing coiled crimps. By this crimping, the entanglement of the fibers in the raised layer portion on the surface of the sheet-like material becomes large.

  In the composite fiber bonded to the side-by-side type, when the polymer (A) and the polymer (B) are polyester-based copolymers, the difference in intrinsic viscosity is preferably 0.002 or more and 1.5 or less. When the difference in intrinsic viscosity is increased by 0.002 or more, a fiber having excellent crimp characteristics can be obtained. On the other hand, when the difference in intrinsic viscosity exceeds 1.5, the crimped property of the obtained fiber is good, but the spun fiber is bent excessively to the high viscosity component side, so that stable spinning is performed for a long time. I can't. Further, it is preferable that at least one of the polymer combinations is a polybutylene terephthalate polymer. Since the polybutylene terephthalate polymer is a polymer having high crystallinity, for example, when polyethylene terephthalate is used as the other polymer, a difference in crystallinity is produced between the two polymers, and crimping tends to occur.

  Here, the polyester polymer referred to in the present invention has a structure obtained by copolymerizing dicarboxylic acids or derivatives thereof and diols or derivatives thereof as a main component. More than 50% by weight relative to the weight of The polyester polymer may contain a copolymer component capable of forming another ester bond. Examples of the copolymerizable compound include dicarboxylic acids such as isophthalic acid, succinic acid, cyclohexanedicarboxylic acid, adipic acid, dimer acid, sebacic acid and 5-isophthalic acid, ethylene glycol, butanediol, neopentyl glycol, cyclohexanedi Examples include diols such as methanol, polyethylene glycol, and polypropylene glycol. Further, if necessary, titanium dioxide serving as a matting agent, silica or alumina fine particles as a lubricant, hindered phenol derivatives as an antioxidant, and coloring pigments may be added.

  The polyethylene terephthalate polymer referred to in the present invention is mainly composed of a structure obtained by copolymerizing terephthalic acid or a derivative thereof and ethylene glycol or a derivative thereof.

  Further, the composite ratio of both components of the polymer (A) and the polymer (B) is a mass ratio, preferably in the range of high viscosity component: low viscosity component = 75: 25 to 35:65 (% by mass), more preferably It is the range of 65: 35-45: 55 (mass%). Within this range, the composite ratio can be appropriately set according to the obtained sheet-like material.For example, in order to obtain a sheet-like material having an excellent soft feeling, the high-viscosity component has a low composite ratio and toughness. What is necessary is just to raise the composite ratio of a high-viscosity component to obtain.

  The intrinsic viscosity of the polyester polymer in the present invention is preferably 0.5 or more and 2.0 or less in the high viscosity component. By setting the intrinsic viscosity to 0.5 or more, a fiber having sufficient strength and elongation can be produced. The upper limit of the intrinsic viscosity is preferably 2.0 or less from the viewpoint of ease of molding such as melt extrusion, production cost, and molecular weight reduction due to molecular chain breakage caused by heat or shear force during the process. On the other hand, the low viscosity component can be stably spun by setting the intrinsic viscosity to 0.3 or more and 1.0 or less.

The intrinsic viscosity as used in the present invention is measured based on the following method. The intrinsic viscosity is measured at a temperature of 25 ° C. by dissolving a sample in orthochlorophenol (hereinafter abbreviated as OCP). (IV value) shall be adopted.
(1) 0.8 g of sample polymer is dissolved in 10 mL of OCP.
(2) The solution is brought to a temperature of 25 ° C., the relative viscosity (η _r ) is obtained by the following equation using an Ostwald viscometer, and the intrinsic viscosity (IV value) is calculated.

η _r = η / η ₀ = (t × d) / (t ₀ × d ₀ )
Intrinsic viscosity (IV value) = 0.0242 η _r +0.2634
Here, η: viscosity of polymer solution η ₀ : viscosity of OCP t: time of dropping of solution (second)
d: density of the solution (g / cm ³ )
t ₀ : OCP fall time (seconds)
d ₀ : Density of OCP (g / cm ³ ).

  The intrinsic viscosity difference of the polyester polymer can be set to a desired viscosity by appropriately adjusting the polymerization time, temperature, catalyst amount and copolymerization component.

  In the present invention, it is important that the average single fiber diameter of the ultrafine fibers is 0.1 μm or more and 10 μm or less from the viewpoint of the flexibility and napped quality of the sheet-like material. When the average single fiber diameter is increased, a sheet-like product having poor surface quality is obtained. Therefore, the average single fiber diameter is preferably 7 μm or less, more preferably 5 μm or less. On the other hand, it is preferably 0.3 μm or more, and more preferably 0.5 μm or more, from the viewpoints of color development after dyeing, dispersibility of fibers during raising treatment such as grinding with sandpaper, and ease of spreading.

  In addition, the average single fiber diameter of the ultrafine fibers is obtained by taking a scanning electron microscope (SEM) photograph of a cross section of the sheet-like material, randomly selecting 100 circular or nearly elliptical fibers, measuring the fiber diameter, and averaging Calculated by calculating the value.

  The sheet-like material of the present invention includes a base material layer and a raised layer. The base material layer preferably has a structure in which fiber bundles made of ultrafine fibers are entangled with each other, that is, a fiber entangled body. The raised layer preferably has a structure in which ultrafine fibers are crimped into a coil shape. In the present invention, the raised layer is a layer formed by the ultrafine fibers in which the sheet-like material is raised, and the base material layer is a layer other than the raised layer of the sheet-like material.

  When the base material layer has a fiber entangled body, it is preferable that the ultrafine fibers constituting the fiber entangled body take the form of a fiber bundle made of ultrafine fibers, that is, an ultrafine fiber bundle. When the ultrafine fibers are bundled, physical strength such as tensile strength and tear strength of the sheet-like material is improved, shape stability is good, and wear resistance is easily exhibited. As a form of the ultrafine fiber bundle, the ultrafine fibers may be somewhat separated from each other, and may be partially bonded or agglomerated in some cases.

[Elastic polymer]
The sheet-like material of the present invention contains 5% by mass or more and 60% by mass or less of a porous elastic polymer with respect to the mass of ultrafine fibers of the fiber entangled body. By containing at least 5% by mass of the elastic polymer with respect to the mass of the ultrafine fiber, it becomes possible to impart an appropriate compression property to the sheet-like material. When the mass of the elastic polymer is more than 60% by mass, the fiber opening property in the napping process is poor, and the flexibility of the sheet-like material is lowered. Furthermore, when the sheet-like material is used after being dyed, there is a difference in the color tone between the fibers of the fiber entangled body after dyeing and the elastic polymer. In terms of environmental considerations, it is not preferable to add a large amount of elastic polymer because the amount of organic matter used in the production process increases, and the smaller the amount of elastic polymer, the more the fibers obtained from recycled materials and plant-derived materials. When used, it can be easily recovered and discarded. A more preferable range of the mass of the elastic polymer is 15% by mass or more and 55% by mass or less.

  For the above-mentioned elastic polymer, pigments such as carbon black, dyes, antifungal agents and antioxidants, UV absorbers, light stabilizers such as light stabilizers, flame retardants, penetrants and lubricants, silica Antiblocking agents such as water and titanium oxide, water repellents, viscosity modifiers, surfactants such as antistatic agents, antifoaming agents such as silicone, fillers such as cellulose, and coagulation regulators, and silica and titanium oxide, etc. Inorganic particles or the like can be contained.

  Examples of the elastic polymer used in the present invention include polyurethane elastomers, polyureas, polyacrylic acid, ethylene / vinyl acetate elastomers and acrylonitrile / butadiene elastomers and styrene / butadiene elastomers, polyvinyl alcohol, and polyethylene glycol. From the viewpoint of compression characteristics, polyurethane elastomers are preferably used. The polymer elastic body can contain a plurality of polymer elastic bodies.

  Examples of the polyurethane elastomer particularly preferably used in the present invention include polyurethane and polyurethane / polyurea elastomer.

  As the polyurethane elastomer used in the present invention, a solvent-based polyurethane elastomer can be used.

  As the polyurethane elastomer used in the present invention, a polyurethane elastomer obtained by a reaction of a polymer diol, an organic diisocyanate and a chain extender is preferably used.

  As the polymer diol, for example, a polycarbonate diol, a polyester diol, a polyether diol, a silicone diol, and a fluorine diol can be employed, and a copolymer combining these can also be used. Among these, from the viewpoint of hydrolysis resistance, it is preferable to use a polycarbonate diol and / or a polyether diol.

  The polycarbonate-based diol can be produced by transesterification of alkylene glycol and carbonate, or reaction of phosgene or chloroformate with alkylene glycol.

  Examples of the alkylene glycol include ethylene glycol, propylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,9-nonanediol, 1,10-decanediol, and the like. Linear alkylene glycol, and branched alkylene glycols such as neopentyl glycol, 3-methyl-1,5-pentanediol, 2,4-diethyl-1,5-pentanediol and 2-methyl-1,8-octanediol Alicyclic diols such as 1,4-cyclohexanediol, aromatic diols such as bisphenol A, glycerin, trimethylolpropane, and pentaerythritol. In the present invention, both polycarbonate-based diols obtained from individual alkylene glycols and copolymerized polycarbonate-based diols obtained from two or more types of alkylene glycols can be employed.

  Examples of the polyester diol include polyester diols obtained by condensing various low molecular weight polyols and polybasic acids.

  Examples of the low molecular weight polyol include ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,3-butanediol, 1,4-butanediol, and 2,2-dimethyl-1,3-propane. Diol, 1,6-hexanediol, 3-methyl-1,5-pentanediol, 1,8-octanediol, diethylene glycol, triethylene glycol, dipropylene glycol, tripropylene glycol, cyclohexane-1,4-diol, and One kind or two or more kinds selected from cyclohexane-1,4-dimethanol can be used.

  Further, addition products obtained by adding various alkylene oxides to bisphenol A can also be used.

  Polybasic acids include, for example, succinic acid, maleic acid, adipic acid, glutaric acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, dodecanedicarboxylic acid, phthalic acid, isophthalic acid, terephthalic acid, and hexahydro One kind or two or more kinds selected from isophthalic acid can be mentioned.

  Examples of the polyether-based diol used in the present invention include polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and copolymer diols obtained by combining them.

  The number average molecular weight of the polymer diol is preferably in the range of 500 or more and 4000 or less when the molecular weight of the polyurethane-based elastomer is constant. By making the number average molecular weight preferably 500 or more, more preferably 1500 or more, it is possible to prevent the sheet-like material from becoming hard. Moreover, the intensity | strength as a polyurethane-type elastomer is maintainable by making a number average molecular weight into 4000 or less, More preferably, 3000 or less.

  Examples of the organic diisocyanate used in the present invention include aliphatic diisocyanates such as hexamethylene diisocyanate, dicyclohexylmethane diisocyanate, isophorone diisocyanate and xylylene diisocyanate, and aromatic diisocyanates such as diphenylmethane diisocyanate and tolylene diisocyanate. These can also be used in combination.

  As the chain extender, amine chain extenders such as ethylenediamine and methylenebisaniline, and diol chain extenders such as ethylene glycol can be preferably used. Moreover, the polyamine obtained by making polyisocyanate and water react can also be used as a chain extender.

  The polyurethane used in the present invention can be used in combination with a crosslinking agent for the purpose of improving water resistance, abrasion resistance, hydrolysis resistance and the like. The cross-linking agent may be an external cross-linking agent added as a third component to the polyurethane-based elastomer, or an internal cross-linking agent that introduces a reaction point that becomes a cross-linked structure in advance in the polyurethane molecular structure. From the viewpoint that the cross-linking points can be formed more uniformly in the polyurethane molecular structure and the reduction in flexibility can be reduced, it is preferable to use an internal cross-linking agent.

  As the crosslinking agent, compounds having an isocyanate group, an oxazoline group, a carbodiimide group, an epoxy group, a melamine resin, a silanol group, and the like can be used.

[Nonwoven fabric]
The nonwoven fabric constituting the sheet-like material of the present invention may be either a short fiber nonwoven fabric or a long fiber nonwoven fabric, but a short fiber nonwoven fabric is preferably used in terms of texture and quality.

  The short fiber nonwoven fabric used in the sheet-like material of the present invention is obtained by forming a laminated web using short fibers with a card and a cross wrapper and then applying a needle punch or a water jet punch or obtained by a papermaking method. As the obtained non-woven fabric, those obtained from a spunbond method, a melt blow method or the like can be appropriately employed.

  The fiber length of the short fiber in the short fiber nonwoven fabric is preferably 25 mm or more and 90 mm or less. By setting the fiber length to 25 mm or more, a sheet-like material having excellent abrasion resistance can be obtained by entanglement. Moreover, by setting the fiber length to 90 mm or less, it is possible to obtain a sheet-like material excellent in compression characteristics and surface quality of the sheet-like material. The fiber length is more preferably 30 mm or more and 80 mm or less.

[Sheet]
The sheet-like material of the present invention preferably has a napped layer on one or both sides of the sheet-like material, and the ultrafine fibers constituting the napped layer preferably have a coiled crimp. When the ultrafine fiber has a coiled crimp, a bulky feeling can be imparted to the sheet-like material.

  The raised length of the raised layer is preferably 200 μm or more and 500 μm or less, more preferably 300 μm or more and 400 μm or less. When the napped length is smaller than 200 μm, a part of the base material layer is exposed and the appearance quality is deteriorated. On the other hand, if the nap length is greater than 500 μm, the surface becomes rough and the appearance deteriorates.

  The average length of the napped length when brushed in the direction of napping with respect to the ultrafine fiber of the napped layer and the average length of napped length when brushed in the direction of 180 ° with respect to the direction of napping of the ultrafine fiber of the napped layer The nap length change rate is preferably 0% or more and 35% or less. If the rate of change exceeds 35%, the direction of the hair is likely to change due to brushing, the direction of the raised hair becomes clear, the visual quality deteriorates depending on the viewing angle, and a uniform surface cannot be obtained.

In addition, in this invention, the change measured by the following method shall employ | adopt the change rate of nap length. The napped direction refers to the direction in which the fiber orientation is greatest in the plane of the napped layer of the sheet.
(1) The brush part has a rectangular shape of 11 cm × 5 cm, the single fiber diameter of the brush part is 50 μm or more and 60 μm or less, and the fiber bundle composed of 30 to 40 single fibers is 3000 Using a rotating head type dust removing brush made of polypropylene / polyethylene terephthalate that is greater than or equal to 4000, brush 5 times with a force of 50N or greater and 70N or less against the ultrafine fibers in the raised layer. It is the direction to lay down the fiber among the directions.
(2) A cross-sectional view of the sheet-like material is photographed (magnification 40 times), 10 points are measured at intervals of 200 μm, and the average value is defined as the napped length X.
(3) Brushing 5 times with a force of 50N or more and 70N or less using the brush in the direction of 180 ° from the direction of the napped against the ultrafine fibers of the napped layer, and in the direction of standing up the fibers even in the napped direction That is.
(4) The napped length Y is calculated by the same method as the napped length X.
(5) For each sample, the nap length change rate (%) is calculated from the following equation.
・ Raised length change rate (%) = (Raised length Y−Raised length X) / Raised length X × 100
The sheet-like material of the present invention can include a reinforcing layer for the purpose of improving the strength of the inner layer portion or the surface thereof. As the reinforcing layer, woven fabrics, knitted fabrics, nonwoven fabrics (including paper), and film-like materials such as plastic films and metal thin film sheets can be employed. In the case of a woven or knitted fabric in which the reinforcing layer is composed of fibers, the average single fiber diameter of the fibers is preferably about 0.1 μm to 20 μm from the viewpoint of the texture of the sheet-like material.

  Examples of the type of fiber yarn constituting the woven or knitted fabric used in the present invention include filament yarn, spun yarn, innovative spun yarn, and mixed composite yarn of filament yarn and spun yarn. Since many yarns are present on the surface of the spun yarn due to its structure, when the nonwoven fabric and the woven fabric are entangled with each other, it becomes a drawback if the yarn falls off and is exposed on the surface. Therefore, it is preferable to use a filament yarn. The filament yarn is roughly classified into a monofilament composed of a single fiber and a multifilament composed of a plurality of filament yarns. In the woven or knitted fabric used in the present invention, it is preferable to use a multifilament. In the case of monofilaments, the stiffness of the fiber becomes too high, and the texture of the sheet-like material may be impaired.

  The total fineness of the fiber yarns constituting the woven or knitted fabric is preferably 50 dtex or more and 150 dtex or less for reasons such as rigidity and basis weight.

The basis weight of the woven or knitted fabric is preferably 20 g / m ² or more and 200 g / m ² or less, more preferably 30 g / m ² or more and 150 g / m ² or less. If the basis weight of the woven or knitted fabric is less than 20 g / m ² , the form of the woven or knitted fabric is poor, and wrinkles are generated when the woven or knitted fabric is inserted between the nonwoven fabric and the woven or knitted fabric is stacked on the surface of the nonwoven fabric, It becomes difficult to laminate uniformly. On the other hand, when the basis weight of the woven or knitted fabric exceeds 200 g / m ² , the structure of the woven or knitted fabric becomes dense, and the entanglement between the nonwoven fabric and the woven or knitted fabric tends to be difficult.

  As the basic structure of the fabric used in the present invention, twill or satin may be used, but a flat structure in which misalignment or the like hardly occurs is preferably used.

  The sheet-like material of the present invention preferably has a napped layer on one or both sides of the sheet-like material, and the ultrafine fibers constituting the napped layer preferably have a coiled crimp. When the ultrafine fiber has a coiled crimp, the sheet-like material can be given a bulky feeling and a stretch property can also be expressed.

  The coiled crimp radius of the ultrafine fiber is preferably an arc shape of 5 μm or more and 100 μm or less, more preferably 90 μm or less, and still more preferably 85 μm or less. When the radius is larger than 100 μm, the crimp becomes weak and the stretchability cannot be obtained. On the other hand, from the viewpoint of surface quality, it is preferably 7 μm or more, more preferably 20 μm or more. When the radius is smaller than 5 μm, the crimp becomes strong and the surface quality deteriorates. Since the ultrafine fibers are crimped in a coil shape, the coverage of the ultrafine fibers on the surface of the sheet-like material is higher than when there is no crimp, and the non-woven fabric under the raised fibers is not visible, and only the raised fibers appear. It has a precise and elegant appearance.

The apparent density of the sheet-like material of the present invention is preferably 0.10 g / cm ³ or more and 0.80 g / cm ³ or less, more preferably 0.20 g / cm ³ or more and 0.70 g / cm ³ or less. . When the apparent density is 0.10 g / cm ³ or more, the denseness and mechanical properties of the sheet-like material are good, and when it is 0.80 g / cm ³ or less, it is possible to avoid the texture becoming hard.

  The thickness of the sheet is preferably 0.1 mm or more and 7 mm or less. By setting the thickness to 0.1 mm or more, preferably 0.3 mm or more, the sheet form has excellent form stability and dimensional stability. On the other hand, when the thickness is 7 mm or less, more preferably 5 mm or less, the sheet-like product is excellent in moldability.

  The sheet-like material of the present invention contains functional agents such as dyes, pigments, softeners, texture modifiers, anti-pilling agents, antibacterial agents, deodorants, water repellents, light proofing agents, and weathering agents. May be.

[Method for producing sheet-like material]
Next, a method for producing the sheet-like material of the present invention will be described.
The method for producing a sheet-like material of the present invention is a method for producing the sheet-like material of the present invention, wherein the following steps (1) and (2) are performed in this order. .
(1) A napping layer is formed by subjecting a non-woven fabric made of ultrafine fibers only in the same direction to form a raised layer, and a non-woven fabric after the napping treatment is obtained. (2) The non-woven fabric after the napping treatment is 110 ° C. or higher and 150 ° C. By performing heat treatment at the following temperature, crimps are expressed in the ultrafine fibers of the raised layer. According to a preferred aspect of the method for producing a sheet-like product of the present invention, the ultrafine fibers have an intrinsic viscosity. This is a bimetallic yarn in which polyesters having different differences are bonded in a side-by-side manner in the fiber length direction, and is obtained from a non-woven fabric composed of ultrafine fiber-expressing fibers. These are described in detail below.

(Ultrafine fiber expression process)
First, in order to obtain the ultrafine fiber constituting the nonwoven fabric, the ultrafine fiber expression type fiber is spun. Examples of the ultrafine fiber expression type fiber include sea-island type composite fiber and exfoliation split type fiber. When sea-island type composite fibers are used, the thermoplastic polymer component having different solubility in a solvent or the like is used as a sea component and an island component, and the sea component is dissolved and removed with a solvent or the like in a later process to make the island component an ultrafine fiber. be able to. Moreover, when using a separation division type | mold fiber, it can be set as an ultrafine fiber by carrying out separation division by physical force, such as a water jet, or swelling of a solvent. Among these, sea-island type composite fibers are preferred in that the ultrafine fiber diameter can be controlled uniformly and the surface appearance of the sheet-like material can be made graceful. Moreover, the sea-island type composite fiber can provide an appropriate gap between the island components, that is, between the ultrafine fibers in the fiber bundle by removing the sea component, and the fiber diameter of the composite fiber per fiber is particularly large. It is preferably used from the viewpoint that small ultrafine fibers can be efficiently expressed and a soft texture or bulkiness can be imparted to the sheet-like material.

  For the production of sea-island type composite fibers, a sea-island-type composite base is used, a polymer inter-array system in which the sea component and the island component are mutually aligned and spun, or the sea component and the island component are mixed. For example, a mixed spinning method in which spinning is performed can be used. Among these, the sea-island type composite fiber by the polymer array system is preferable in that ultrafine fibers having a uniform fineness can be obtained.

  In the method for producing a sheet-like material according to the present invention, the ultrafine fiber-expressing fiber is a sea-island type composite fiber, and two types of polyester polymers having an island component having an intrinsic viscosity difference are side-by-side type along the fiber length direction It is preferable that the composite fiber is a composite fiber having a core-sheath structure in which two types of polyester polymers having different intrinsic viscosities are decentered. In the island component, a composite fiber in which two types of polyester polymers having a difference in intrinsic viscosity are bonded side-by-side along the fiber length direction, or a core in which two types of polyester polymers having a difference in intrinsic viscosity are eccentric By being a composite fiber forming a sheath structure, latent crimped island component fibers can be obtained.

  Examples of the sea component of the sea-island composite fiber include polyethylene, polypropylene, polystyrene, copolymer polyester obtained by copolymerizing sodium sulfoisophthalate, polyethylene glycol, and the like, polylactic acid, and polyvinyl alcohol.

  In the method for producing a sheet-like product of the present invention, the mass ratio of the sea component to the island component when the sea-island composite fiber is used is preferably in the range of sea component: island component = 5: 95 to 80:20. If the mass ratio of the sea component is less than 5 mass%, the island component may be insufficiently thinned. Further, when the mass ratio of the sea component exceeds 80 mass%, the productivity may be lowered because the ratio of the eluted component is large. The mass ratio of the sea component and the island component is more preferably in the range of sea component: island component = 10: 90 to 60:40.

  In the method for producing a sheet-like product of the present invention, the number of ultrafine fibers in the ultrafine fiber bundle generated by expressing ultrafine fibers from one sea-island type composite fiber is 10 / bundle to 9000 / bundle. More preferably, the number is 10 / bundle to 4000 / bundle. When the number of ultrafine fibers is less than 10 / bundle, the fineness of the ultrafine fibers is poor, and for example, mechanical properties such as wear tend to be reduced. Further, when the number of ultrafine fibers is more than 9,000 / bundle, the spreadability at the time of napping is lowered, and the fiber distribution on the napped surface tends to be non-uniform.

  From the viewpoint of the density of ultrafine fibers, the degree of fiber density in the ultrafine fiber bundle is preferably 30 (lines / μm) or more and 1000 (lines / μm) or less, more preferably 50 (lines / μm) or more and 700. (Book / μm) or less. The degree of fiber density is calculated by (number of fibers in the ultrafine fiber bundle) × (single fiber diameter) and is an index of the size of the ultrafine fiber bundle. As described above, by setting the fiber density in the ultrafine fiber bundle to 30 (lines / μm) or more and 1000 (lines / μm) or less, the processing operability when forming the fiber entanglement is good, and the fineness of the ultrafine fiber bundle is high. Sexuality is improved.

  Next, the stretched sea-island type composite fiber is preferably crimped and cut into a predetermined length to obtain a raw nonwoven fabric. A usual method can be used for crimping and cutting.

The non-woven raw cotton obtained in this way is carded, passed through a thin sheet of cotton, and laminated with a cross wrapper to obtain a laminated fiber web.
Thereafter, in order to obtain a fiber entangled body, a method in which the laminated fiber web is entangled with a needle punch or a water jet punch, a spun bond method, a melt blow method, a paper making method, or the like can be employed. Among them, a method of entanglement of a laminated fiber web composed of ultrafine fiber-expressing fibers with a needle punch or a water jet punch is preferably used in order to form the ultrafine fiber bundle as described above.

It is preferable that the apparent density of the fiber entangled body composed of the ultrafine fiber generating fiber after the needle punching process or the water jet punching process is 0.15 g / cm ³ or more and 0.40 g / cm ³ or less. By setting the apparent density to 0.15 g / cm ³ or more, a fiber entangled body having excellent shape stability and dimensional stability can be obtained. On the other hand, when the apparent density is 0.40 g / cm ³ or less, preferably 0.30 g / cm ³ or less, a sufficient space for applying the elastic polymer can be maintained between the fibers.

  The fiber entangled body composed of the ultrafine fiber-expressing fibers thus obtained is preferably subjected to heat shrinkage treatment with dry heat or wet heat, or both from the viewpoint of densification, and further densified. It is. Further, the fiber entangled body can be compressed in the thickness direction by calendaring or the like.

  The treatment (desealing treatment) for expressing ultrafine fibers from the sea-island type composite fibers can be performed by immersing the sea-island type composite fibers in a solvent and squeezing them. As the solvent for dissolving the sea component, when the sea component is polyethylene, polypropylene, or polystyrene, an organic solvent such as toluene or trichloroethylene can be used. Further, when the sea component is a copolyester or polylactic acid, an aqueous alkali solution such as sodium hydroxide or hot water can be used. For the treatment for developing ultrafine fibers, a continuous dyeing machine, a vibro-washer type seawater removal machine, a liquid dyeing machine, a Wins dyeing machine, a jigger dyeing machine, or the like can be used.

(Raising process)
The raising treatment for forming the napped fibers of the ultrafine fibers on the surface of the sheet-like material of the present invention can be performed by a grinding method using a sandpaper or a roll sander. Before the raising treatment, a lubricant such as a silicone emulsion may be applied to the sheet.

  In addition, applying an antistatic agent before the above-mentioned raising treatment tends to make it difficult for the grinding powder generated from the sheet-like material to be deposited on the sandpaper by grinding.

  The sheet-like material may be obtained by dividing into half or several sheets in the thickness direction of the sheet-like material before performing the raising treatment.

  It is important that the sheet-like material of the present invention has napping on at least one surface of the sheet-like material. The sheet-like material has a flat and uniform surface by performing the raising treatment only from the same direction. When the raising process from a reverse direction is also included, the opening property of the fiber which comprises a napped part falls, and a uniform surface quality cannot be obtained.

(Crimp expression process)
The method for producing a sheet-like product of the present invention includes a step of causing crimps in the ultrafine fibers of the napped layer by subjecting the nonwoven fabric after the raising treatment to a heat treatment at a temperature of 110 ° C. to 150 ° C.

  In the method for producing a sheet-like product of the present invention, it is important that the crimp expression step is performed after the ultrafine fiber expression step and the raising step. For example, if the nonwoven fabric is subjected to a heat treatment at a temperature of 100 ° C. or more before the ultrafine fiber expression step, crimps are expressed after the sea components are dissolved, and the crimped fibers are stretched when the nap processing is performed in the subsequent steps. It becomes difficult to obtain a napped surface on which the desired crimped ultrafine fibers are present in the method for producing a sheet-like product of the present invention.

  In the crimping step, the heat treatment temperature is preferably 110 ° C. or higher and 150 ° C. or lower, more preferably 120 ° C. or higher and 130 ° C. or lower. Heat treatment and squeezing tend to cause crimping of ultrafine fibers.

  The dye can be selected according to the type of fiber constituting the sheet-like material. For example, disperse dyes can be used for polyester fibers, acidic dyes or metal-containing dyes can be used for polyamide fibers, and combinations thereof can be used.

  Moreover, it is also a preferable aspect to use a dyeing assistant when dyeing the sheet-like material. By using a dyeing assistant, the uniformity and reproducibility of dyeing can be improved. In addition, a finishing treatment using a softening agent such as silicone, an antistatic agent, a water repellent, a flame retardant, a light proofing agent, and an antibacterial agent can be performed in the same bath or after dyeing.

  Next, the sheet-like material of the present invention and the manufacturing method thereof will be described more specifically using examples. Next, the evaluation methods used in the examples and the measurement conditions will be described.

(1) Polymer melt flow rate (MFR)
4-5 kg of sample pellets are placed in a cylinder of an MFR electric furnace and the amount of resin extruded in 10 minutes under the conditions of a load of 2160 gf and a temperature of 285 ° C. using a Toyo Seiki melt indexer (S101) (g ) Was measured. The same measurement was repeated 3 times, and the average value was defined as MFR.

(2) Average single fiber diameter A cross section obtained by cutting the sheet-like material in the thickness direction was used as an observation surface, and observed with a scanning electron microscope (SEM, VE-7800 manufactured by Keyence Corporation). The fiber diameter was measured and the average value was calculated.

(3) Crimp radius Using a scanning electron microscope (SEM, VE-7800, manufactured by Keyence Corporation), the surface of the sheet is photographed (magnification 100 times), and the radius of the crimped and arcuate fiber is measured. did. The n number was 20, and the average value was obtained. When the arc shape is a part of a circle and the circumferential portion of the arc shape does not exceed 1/2 of the entire circle, the fiber is excluded from the measurement subject as not being a crimped fiber. It was.

(4) Fabric weight of sheet-like material Measured by the method described in JIS L 1096 (1999) 8.4.2. A test piece of 20 cm × 20 cm to 5 sheets collected, weighed respective mass (g), representing the average value in 1 m ² per mass (g / ^{m 2).}

(5) Thickness of sheet-like material Using a thickness gauge with a 0.01-mm scale (disk diameter of 9 mm or more), 5 points were measured at equal intervals in the sheet width direction under a load of 10 kPa, and the average value was obtained.

(6) Napping length Using a scanning electron microscope (SEM, VE-7800 manufactured by Keyence Corporation), a cross-sectional view of the sheet-like material was taken (magnification 40 times), 10 points were measured at intervals of 200 μm, and the average value was obtained. Was defined as napped length.

(7) Evaluation of surface quality The surface quality of the obtained sheet-like material was evaluated by 10 panelists, evaluated according to the following criteria, and the evaluation result with the largest number of people was adopted. The surface quality is evaluated by placing a sheet-like object 3 on an inspection table 2 in a position parallel to the floor surface 1 as shown in FIG. The sheet-like material was visually confirmed and judged at an angle of 45 ° from the plane of the inspection table with respect to the sheet-like material 3 so that the distance 4 was 50 cm. In addition, the inspection table has a 32 W fluorescent lamp 6 vertically 150 cm above the upper surface of the inspection table, and the quality evaluation was performed directly below the fluorescent lamp 6.
4: The surface of the napped is unclear and uniform surface 3: The surface of the napped is unclear and not uniform surface 2: The surface of the napped is clear and uniform surface 1: The direction of napped is clear and uniform Not surface (8) Rate of change of napped length For the evaluation of rate of change of napped length of the obtained sheet-like material, a rotating head type dust removing brush made by Seiwa Pro Co., Ltd. that satisfies the above requirements was used.

[Example 1]
(raw cotton)
Polybutylene terephthalate having an intrinsic viscosity (IV) of 1.750 as an island component (abbreviated as “PBT” in Table 1; the same applies hereinafter) and polyethylene terephthalate having an intrinsic viscosity (IV) of 0.510 ( In Table 1, it is abbreviated as “low IV PET. The same shall apply hereinafter.) Are used separately melted, and the Vicat softening point measured according to JIS K7206 (1999) as a sea component is 100 ° C. Then, using a polystyrene (PSt) having an MFR of 120 g / 10 min and a sea-island type composite base having 16 islands, a fiber that is melt-spun at an island / sea mass ratio of 80/20 is obtained by a roller plate method. After drawing and crimping under normal conditions, the fiber was cut into a length of 51 mm to obtain a raw material of sea-island type composite fiber having an average single fiber diameter of 26 μm.

(Nonwoven fabric composed of ultrafine fibers)
Using this raw material of sea-island type composite fiber, a laminated fiber web is formed through a card and cross wrapping process, needle punched at a punch number of 600 / cm ² , and then needle punched at a punch number of 3000 / cm ^2. As a result, a sheet-like material having a basis weight of 470 g / m ² and a thickness of 2.0 mm was obtained.

(Sheet)
After shrinking the nonwoven fabric with hot water at a temperature of 98 ° C., the nonwoven fabric was impregnated with an aqueous solution of PVA (polyvinyl alcohol) having a concentration of 12% and dried with hot air at a temperature of 120 ° C. for 10 minutes. A non-woven fabric having a PVA mass of 30 mass% with respect to the mass was obtained. The nonwoven fabric obtained in this manner was immersed in trichlorethylene to dissolve and remove sea components to obtain a nonwoven fabric (sea removal sheet) made of ultrafine fibers. The nonwoven fabric (sea removal sheet) made of ultrafine fibers thus obtained is immersed in a DMF (dimethylformamide) solution of polycarbonate polyurethane having a solid content adjusted to 12%, and then in an aqueous solution having a DMF concentration of 30%. To solidify the polyurethane. Thereafter, PVA and DMF were removed with hot water, and dried with hot air at a temperature of 110 ° C. for 10 minutes to obtain a sheet-like material having a polyurethane mass of 27 mass% with respect to the mass of the ultrafine fibers comprising the island components. .

  After that, the sheet-like material is cut in half in the thickness direction, and the surface opposite to the half-cut surface is buffed at a buffing speed of 500 m / min and a sheet conveying speed of 5.0 m / min using 240 mesh sandpaper from the same direction. The napped surface was formed.

  The sheet-like material thus obtained is subjected to crimping treatment and dyeing simultaneously under a temperature condition of 130 ° C. using a liquid dyeing machine, and then dried using a dryer to obtain a sheet-like material. I got a thing.

  The obtained sheet-like material has a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm, and as a result of observing the napped layer portion, it is confirmed that crimps are expressed in the ultrafine fibers constituting the napped layer. confirmed. Moreover, by the SEM observation (40 times) of the cross section, the length of napped length was 230 μm and the change rate was 6%. The surface quality evaluation of the sheet-like material was “4”. The results are shown in Table 1.

[Example 2]
(raw cotton)
Polyethylene terephthalate having an intrinsic viscosity (IV) of 0.780 as an island component (in Table 1, abbreviated as “high IV PET”, the same shall apply hereinafter) and polyethylene terephthalate having an intrinsic viscosity (IV) of 0.510 A raw cotton of sea-island type composite fiber was obtained in the same manner as in Example 1 except that ("low IV PET") was melted separately and used.

(Nonwoven fabric composed of ultrafine fibers)
Using this raw material of sea-island type composite fiber, a laminated fiber web is formed through a card and cross wrapping process, needle punched at a punch number of 600 / cm ² , and then needle punched at a punch number of 3000 / cm ^2. As a result, a sheet-like material having a basis weight of 600 g / m ² and a thickness of 2.7 mm was obtained.

(Sheet)
A sheet-like material was obtained in the same manner as Example 1.

  The obtained sheet-like material has a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm, and as a result of observing the napped layer portion, it is confirmed that crimps are expressed in the ultrafine fibers constituting the napped layer. confirmed. Moreover, by the SEM observation (40 times) of the cross section, the length of napped length was 310 μm and the change rate was 8%. The surface quality evaluation of the sheet-like material was “4”. The results are shown in Table 1.

[Example 3]
A sheet-like material was obtained in the same manner as in Example 2 except that the paper used for buffing was changed to 180 mesh.

  The obtained sheet-like material has a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm, and as a result of observing the napped layer portion, it is confirmed that crimps are expressed in the ultrafine fibers constituting the napped layer. confirmed. Moreover, by the SEM observation (40 times) of the cross section, the length of the napped length was 480 μm and the change rate was 22%. The surface quality evaluation of the sheet-like material was “4”. The results are shown in Table 1.

[Example 4]
A sheet-like material was obtained in the same manner as in Example 1 except that the paper used for buffing was changed to 180 mesh.

  The obtained sheet-like material has a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm, and as a result of observing the napped layer portion, it is confirmed that crimps are expressed in the ultrafine fibers constituting the napped layer. confirmed. Moreover, by the SEM observation (40 times) of the cross section, the length of napped length was 250 μm and the change rate was 30%. The surface quality evaluation of the sheet-like material was “4”. The results are shown in Table 1.

[Comparative Example 1]
(raw cotton)
Polyethylene terephthalate having an intrinsic viscosity (IV) of 0.718 as an island component (in Table 1, abbreviated as “medium IV PET”, hereinafter the same), and sea component according to JIS K7206 (1999). Polystyrene (PSt) having a measured Vicat softening point of 100 ° C. and an MFR of 120 g / 10 min was melt-spun at an island / sea mass ratio of 80/20 using a sea-island type composite base having 24 islands. The fiber was drawn by a roller plate method under normal conditions and crimped, and then the fiber was cut to a length of 51 mm to obtain a sea-island composite fiber raw cotton having an average single fiber diameter of 26 μm.

(Nonwoven fabric composed of ultrafine fibers)
Using this raw material of sea-island type composite fiber, a laminated fiber web is formed through a card and cross wrapping process, needle punched at a punch number of 600 / cm ² , and then needle punched at a punch number of 3000 / cm ^2. As a result, a sheet-like material having a basis weight of 650 g / m ² and a thickness of 2.9 mm was obtained.

(Sheet)
A sheet-like material was obtained in the same manner as Example 1.

  The obtained sheet-like material had a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm. As a result of observing the napped layer portion, no crimp was expressed in the ultrafine fibers constituting the napped layer. Moreover, by the SEM observation (40 times) of the cross section, the length of napped length was 600 μm and the change rate was 59%. The surface quality evaluation of the sheet-like material was “2”. The results are shown in Table 1.

[Comparative Example 2]
A sheet-like material was obtained in the same manner as in Example 2 except that the buffing direction was changed.

  The obtained sheet-like material had a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm. As a result of observing the napped layer portion, no crimp was expressed in the ultrafine fibers constituting the napped layer. Further, by SEM observation (40 times) of the cross section, the length of napped length was 260 μm and the rate of change was 15%. The surface quality evaluation of the sheet-like material was “1”. The results are shown in Table 1.

[Comparative Example 3]
A sheet-like material was obtained in the same manner as in Example 2 except that the dyeing temperature was 98 ° C.

  The obtained sheet-like material had a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm. As a result of observing the napped layer portion, no crimp was expressed in the ultrafine fibers constituting the napped layer. Moreover, by the SEM observation (40 times) of the cross section, the length of the napped length was 430 μm and the change rate was 39%. The surface quality evaluation of the sheet-like material was “2”. The results are shown in Table 1.

[Comparative Example 4]
A sheet-like material was obtained in the same manner as in Example 1 except that the paper used for buffing was changed to 600 mesh and the baffle speed was changed to 1000 m / min.

  The obtained sheet-like material had a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm. As a result of observing the napped layer portion, no crimp was expressed in the ultrafine fibers constituting the napped layer. Moreover, by the SEM observation (40 times) of the cross section, the length of napped length was 170 μm and the change rate was 17%. The surface quality evaluation of the sheet-like material was “3”. The results are shown in Table 1.

[Comparative Example 5]
A sheet-like material was obtained in the same manner as in Example 1 except that the paper used for buffing was changed to 120 mesh.

  The obtained sheet-like material had a sheet thickness of 0.7 mm and an average single fiber diameter of 4.4 μm. As a result of observing the napped layer portion, no crimp was expressed in the ultrafine fibers constituting the napped layer. Moreover, by the SEM observation (40 times) of the cross section, the length of napped length was 550 μm and the change rate was 25%. The surface quality evaluation of the sheet-like material was “1”. The results are shown in Table 1.

  Since the sheet-like material of the present invention has a uniform surface, the interior material has a very elegant appearance as a skin material such as furniture, chairs and wall materials, and ceilings and interiors in vehicle interiors such as automobiles, trains and airplanes. Can be suitably used. Furthermore, in the sheet-like material of the present invention, a large number of gaps of about several nm to 500 nm are created between single fibers or intertwined fibers, and thus may exhibit specific properties such as a porous material. It can also be used for other purposes.

1: Floor surface 2: Inspection table 3: Sheet-like object 4: Line connecting the position to be visually confirmed and sheet-like object 5: Position to be visually confirmed 6: Fluorescent lamp 7: Vertical line from the sheet-like object to the fluorescent lamp

Claims (4)

  A sheet-like material composed of an ultrafine fiber having an average single fiber diameter of 0.1 μm or more and 10 μm or less and an elastic polymer, wherein the sheet-like material is composed of a base material layer and a raised layer, and constitutes the raised layer The ultrafine fibers have crimps, the length of the raised layer of the raised layer is not less than 200 μm and not more than 500 μm, and the average length of the raised hair when brushed in the direction of the raised fiber with respect to the ultrafine fiber of the raised layer A sheet-like material characterized in that the rate of change of the napped length of the napped length when brushed in a direction of 180 ° with respect to the napped direction of the ultrafine fibers of the napped layer is 0% or more and 35% or less. .   The sheet-like material according to claim 1, wherein the ultrafine fibers constituting the sheet-like material are bimetallic yarns in which polyesters having different intrinsic viscosities are bonded in a side-by-side manner in the fiber length direction. A method for producing a sheet-like material according to claim 1 or 2, wherein the following steps (1) and (2) are performed in this order.
(1) A raising step of forming a raised layer by subjecting a nonwoven fabric composed of ultrafine fibers only from the same direction to obtain a nonwoven fabric after the raising treatment (2) 110 ° C. or more and 150 ° C. or less of the nonwoven fabric after the raising treatment A step of expressing crimps in the ultrafine fibers of the raised layer by performing a heat treatment at a temperature of   The said ultrafine fiber is a bimetallic thread | yarn which bonded the polyester from which an intrinsic viscosity difference differs in the side-by-side type | mold to the fiber length direction, Comprising: It is obtained from the nonwoven fabric which consists of an ultrafine fiber expression type | formula fiber. Manufacturing method of sheet-like material.

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