JP3201671B2 - Manufacturing method of composite nonwoven fabric - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates is related to the mechanical properties, method for producing a composite nonwoven fabric having excellent dimensional stability and flexibility.

[0002]

2. Description of the Related Art Conventionally, various composite nonwoven fabrics in which a short fiber card web is laminated and composited on a base cloth are known. For example, Japanese Patent Application Laid-Open Nos. 53-114975 and 53-12
No. 4601 proposes a composite nonwoven fabric in which a woven or knitted fabric is used as a base fabric, and a nonwoven web made of split split conjugate short fibers or a microfiber nonwoven web obtained by a melt blown method is laminated and composited thereon. However, the use of these composite nonwoven fabrics is limited to synthetic leather, and the cost is extremely high and the economic efficiency is poor. on the other hand,
Japanese Unexamined Patent Publication (Kokai) No. 63-21354 discloses that a long fiber nonwoven fabric obtained by a spunbond method is used as a base fabric, and a long fiber present on one side or both sides is partially cut to form a fiber end. A composite nonwoven fabric has been proposed in which fibers of a short fiber nonwoven web laminated on a fabric are entangled. However, this composite nonwoven fabric has a problem that the mechanical properties are deteriorated because the long fibers are partially cut, and the inherent surface smoothness of the long fiber nonwoven fabric is also deteriorated.

[0003]

SUMMARY OF THE INVENTION The present invention solves the above problems and provides a composite nonwoven fabric which has excellent mechanical properties, dimensional stability and flexibility and is suitable not only for industrial materials but also for general materials. It is an object of the present invention to provide a method capable of efficiently manufacturing it.

[0004]

Means for Solving the Problems The present inventors have made intensive studies to solve the above-mentioned problems, and as a result, have reached the present invention. That is, the present invention provides the use of a 50 to 80 ° C. lower temperature heat embossing roll in the melting point of the polymer surface temperature the formed synthetic long fiber nonwoven web having a lowest melting point in the constituent fibers by scan Panbondo method rolls Linear pressure 5-30kg / c
m, a partial hot-pressing treatment is performed to form a synthetic long-fiber non-woven web layer A, and then a short-fiber non-woven web layer B is laminated on both sides of the obtained synthetic long-fiber non-woven web layer A. As a one-stage treatment, a high-pressure liquid flow treatment at a pressure of 5 to 30 kg / cm ² G is performed to preliminarily entangle the constituent fibers of the short-fiber nonwoven web layer B, and then a pressure of 40 is applied as a second-stage treatment. A high-pressure liquid flow treatment of up to 150 kg / cm ² G so that the constituent fibers of the synthetic long-fiber nonwoven web layer A and the constituent fibers of the short-fiber nonwoven web layer B are three-dimensionally entangled with each other;
Further, the gist of the present invention is a method for producing a composite nonwoven fabric, in which the constituent fibers of the short fiber nonwoven web layer B are three-dimensionally entangled and integrated as a whole.

Next, the present invention will be described in detail. The long fibers constituting the synthetic long-fiber nonwoven web layer A in the present invention are made of a polyolefin-based polymer, polyester-based polymer or polyamide-based polymer having a fiber-forming property. Examples of the polyolefin polymer include aliphatic α-monoolefins having 2 to 18 carbon atoms, such as ethylene, propylene, butene-1, pentene-1,3-methylbutene-1, hexene-1, octene-1, and dodecene. A homopolyolefin polymer composed of 1, octadecene-1 is exemplified. This aliphatic α-monoolefin can be used in other ethylenically unsaturated monomers such as butadiene,
It may be a polyolefin copolymer in which similar ethylenically unsaturated monomers such as isoprene, pentadiene-1,3, styrene, and α-methylstyrene are copolymerized. In the case of a polyethylene-based polymer, ethylene may be copolymerized with propylene, butene-1, hexene-1, octene-1, or a similar higher α-olefin at 10% by weight or less. In the case of a polypropylene polymer, ethylene or a similar higher α-olefin may be copolymerized in an amount of 10% by weight or less with respect to propylene. If the weight percentage is exceeded, the melting point of the copolymer decreases, and the mechanical properties and dimensional stability of the composite nonwoven fabric obtained by using a nonwoven web composed of long fibers of these copolymers when used under high temperature conditions are reduced. It is not preferable because the property is lowered. As the polyester polymer, an aromatic dicarboxylic acid such as terephthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid or an aliphatic dicarboxylic acid such as adipic acid or sebacic acid or an ester thereof is used as an acid component; Ethylene glycol, diethylene glycol, 1.4-butadiol, neopentyl glycol, cyclohexane-1
A homopolyester polymer or copolymer containing a diol compound such as 4-dimethanol as an ester component is exemplified. In addition, paraoxybenzoic acid, 5-sodium sulfoisophthalic acid, polyalkylene glycol, pentaerythritol, bisphenol A, etc. may be added or copolymerized to these polyester polymers. Examples of polyamide polymers include polyimino-1-oxotetramethylene (nylon 4), polytetramethylene adipamide (nylon 46), polycapramide (nylon 6), polyhexamethylene adipamide (nylon 66), and polyundecana Mid (nylon 11),
Examples thereof include polylaurolactamide (nylon 12), polymethaxylene adipamide, polyparaxylylene decanamide, polybiscyclohexylmethanedecanamide, and a polyamide copolymer having these monomers as a constitutional unit. In particular, in the case of polytetramethylene adipamide, polytetramethylene adipamide is copolymerized with other polyamide components such as polycapramid, polyhexamethylene adipamide, polyundecamethylene terephthalamide and the like in an amount of 30 mol% or less. It may be a tetramethylene adipamide copolymer. When the copolymerization ratio of the other polyamide component exceeds 30 mol%, the melting point of the copolymer decreases, and a composite nonwoven fabric obtained using a nonwoven web composed of long fibers of these copolymers is used under high temperature conditions. When this is done, the mechanical properties and dimensional stability decrease, which is not preferable. In the present invention, if necessary, the fiber-forming thermoplastic polymer may contain, for example, a matting agent, a pigment, a flame retardant, a deodorant, a light stabilizer, a heat stabilizer, and an antioxidant. Various additives can be added within a range that does not impair the effects of the present invention.

[0006] The long fibers constituting the web layer A in the present invention are composed of the above-mentioned polymer having a fiber-forming property. And two or more different polymers selected from the above may be blends blended within a range that does not impair melt spinnability. Examples of the blend include a blend of a polyester polymer and a polyolefin polymer, and a blend of two different polyamide polymers. In particular, the former case is preferable because shrinkage of an unoriented polyester component immediately after melt spinning can be suppressed. Further, the form of the long fiber may be such that two different polymers selected from the above-mentioned polymers are arranged in a core-sheath type or a parallel type. In this composite, for example, a core-sheath type in which a polyethylene terephthalate polymer is disposed in a core portion and a polyethylene polymer is disposed in a sheath portion, or a parallel type composed of a polycapramid polymer and a polyhexamethylene adipamide polymer. Form.

The long fibers constituting the web layer A in the present invention are composed of the above-mentioned polymer having a fiber-forming property and have a single fiber fineness of 1.5 to 8.0 denier.
When the single-fiber fineness is less than 1.5 denier, the mechanical properties of the obtained composite nonwoven fabric are reduced, and the spinning property is reduced in the melt spinning process. The texture of the obtained web becomes hard, so that a composite nonwoven fabric having high flexibility cannot be obtained, which is not preferable. Therefore, in the present invention, the single fiber fineness is preferably 1.5 to 8.0 denier, and more preferably 2.0 to 5.0 denier.

The web layer A in the present invention is composed of the long fibers, and the constituent fibers are partially heat-welded. This partial thermal pressing means that the web corresponding to the engraving pattern is passed by passing a web between a roll which is heated and has an engraving pattern imprinted on its surface, that is, an embossing roll, and a heated metal roll having a smooth surface. The constituent fibers are thermally bonded to each other. More specifically, this partial heat-welding has a specific area with respect to the total surface area of the web layer A, i.e. the individual heat-welded areas do not necessarily have to be circular in shape but have a specific shape. ~
It has an area of 1.0 mm ² , and its density, that is, the pressure contact density is ² to 80 points / cm ^2, preferably 4 to 60 points / cm ²
Good thing. This contact density is 2 points / cm ²
When the pressure is less than 80, the mechanical properties and shape retention of the web after the heat welding are not improved, and when the pressure contact density exceeds 80 points / cm ² , the flexibility and bulkiness are not improved, and neither is preferable. . Further, the ratio of the area of the entire heat-welded region to the entire surface area of the web layer A, that is, the contact area ratio is 2 to 30%, preferably 4 to 20%. If the pressed area ratio is less than 2%, the dimensional stability of the web after hot pressing is not improved, and therefore, the dimensional stability of the composite nonwoven fabric obtained by laminating the web layer B on the web layer A is inferior. , Not preferred.

The web layer A in the present invention preferably has a basis weight of 10 to 200 g / m ² . If the basis weight is less than 10 g / m ² , the degree of dense overlap between the long fibers is low, and the formation of a composite nonwoven fabric obtained by laminating the short fiber non-woven web layer B on the web layer A and reducing the composition is reduced. On the other hand, when the basis weight exceeds 200 g / m ² , when the web layer B is laminated on the web layer A and subjected to the high-pressure liquid flow treatment, all the constituent fibers of the web layer A and the constituent fibers of the web layer B are three-dimensionally. They are not sufficiently entangled, are not integrated as a whole, and are not preferable. Therefore, in the present invention, the basis weight is 10 to 200 g / m ^2, preferably ² g / m 2.
It is good to be 0-100 g / m < ² >.

[0010] The short fiber nonwoven web layer B in the present invention comprises:
It is composed of natural fibers such as cotton and hemp or natural pulp, recycled short fibers typified by various rayons, and short fibers made of a synthetic polymer such as polyester, polyamide or polyolefin. The web may be composed of a single material selected from the short fiber materials, or may be a mixture of a plurality of types of materials. This web layer B has a basis weight of 10 to 1
It is preferably 00 g / m ² . The basis weight is 10
If the weight is less than g / m ² , the obtained web does not have good shape retention, whereas if the basis weight exceeds 100 g / m ² , the three-dimensional structure of the fiber constituting the web layer A and the fiber constituting the web layer B becomes three-dimensional. Neither entanglement nor three-dimensional entanglement between the constituent fibers of the web layer B can be sufficiently obtained, and neither is preferable.

As described above, the composite nonwoven fabric obtained in the present invention has a short-fiber nonwoven web layer B laminated on both sides of a synthetic long-fiber nonwoven web layer A having the above-mentioned heat-welded region.
The constituent fibers of the web layer A and the constituent fibers of the web layer B are three-dimensionally entangled with each other, and the constituent fibers of the web layer B are three-dimensionally entangled with each other, and are integrated as a whole. . The three-dimensional entanglement is formed by a known so-called high-pressure liquid flow treatment, whereby the form of the nonwoven fabric is maintained, and a highly flexible composite nonwoven fabric can be obtained. In the present invention, the web layers B laminated on both sides of the web layer A may be made of the same material, or may be made of different materials.

[0012] The composite nonwoven fabric of the present invention, in the following ways:
You manufacture. That is, using a hot embossing roll having a surface temperature of 50 to 80 ° C. lower than the melting point of the polymer having the lowest melting point among the constituent fibers of the synthetic long-fiber nonwoven web layer formed by the spunbond method, 5-30k
g / cm and subjected to a partial hot pressing treatment to form a synthetic long-fiber non-woven web layer A, and then laminating a short-fiber non-woven web layer B on both sides of the obtained synthetic long-fiber non-woven web layer A ,
The constituent fibers of the synthetic long-fiber nonwoven web layer A and the constituent fibers of the short-fiber nonwoven web layer B are three-dimensionally entangled with each other by high-pressure liquid flow treatment, and the short-fiber nonwoven web layer B is formed. This is a method in which fibers are entangled three-dimensionally and integrated as a whole. First, the synthetic long-fiber nonwoven fabric web layer A is manufactured by a spun bond method. That is, a polyolefin-based polymer, a polyester-based polymer or a polyamide-based polymer having the fiber-forming property alone, or a blend of two or more different polymers selected from the above-mentioned polymers. Alternatively, two different polymers selected from the above polymers are melt-spun so as to be arranged in a core-sheath type or a parallel type, and after cooling the melt-spun polymer stream, the air sucker is cooled. After taking up the material at a take-up speed of 3000 to 6000 m / min using a take-up means such as the above, the fiber is opened, collected and deposited on a moving collecting surface, and the single fiber fineness is 1.5 to 8.0. The web is made of denier single fiber, and the surface temperature of the obtained web is 50 to 80 higher than the melting point of the polymer having the lowest melting point among the constituent fibers.
The web layer A is obtained by performing a hot pressing process using a hot embossing roll at a temperature lower by ° C. When the melt spinning is performed by the spun bond method, the take-off speed is preferably 3000 to 6000 m / min. When the take-off speed is less than 3000 m / min, the degree of molecular orientation of the long fibers does not sufficiently increase, so that the mechanical properties and dimensional stability of the obtained web are not improved.
If the take-up speed exceeds 6000 m / min, the spinnability at the time of melt spinning decreases, and both are not preferred.

When the web is subjected to hot pressing using a hot embossing roll, the hot pressing area does not necessarily have to be a circular shape, but its area is 0.1 to 1.0.
mm ² , the density, ie, the pressure contact density is 5 to 100 points /
cm ^2, preferably 10 to 80 points / cm ² , and the ratio of the area of the entire heat-welded region to the total surface area of the web layer, that is, the contact area ratio is 5 to 50%, preferably 8 to 40%. If the pressure junction density is less than 5 points / cm ² , the mechanical properties and the shape retention of the web after hot pressing are not improved, while if the pressure junction density exceeds 100 points / cm ² , the web layer A The flexibility and bulkiness of the composite nonwoven fabric obtained by laminating the web layer B and subjecting it to high-pressure liquid flow treatment are not improved, and the workability during high-pressure liquid flow treatment is inferior. If the pressed area ratio is less than 5%, the dimensional stability of the web after hot pressing is not improved, and therefore, the dimensional stability of the composite nonwoven fabric obtained by laminating the web layer B on the web layer A is inferior. ,
On the other hand, if the pressed area ratio exceeds 50%, the workability in laminating the web layer B on the web layer A and performing the high-pressure liquid flow treatment is inferior, and neither is preferable. Further, the surface temperature of the roll is preferably 50 to 80 ° C. lower than the melting point of the polymer having the lowest melting point in the fiber constituting the web, and the linear pressure of the roll is preferably 5 to 30 kg / cm. The conditions of the temperature and the linear pressure are particularly important. If the difference between the temperature and the melting point of the polymer exceeds 80 ° C. and the linear pressure is less than 5 kg / cm, the effect of the heat-welding treatment is poor, and the obtained web Layer A
The dimensional stability of the composite nonwoven fabric obtained by laminating the short fiber non-woven web layer B on the web layer A and combining the web layer A with the web layer A does not improve. Is less than 50 ° C. and the linear pressure is 10 kg /
cm, the effect of the thermal pressing treatment becomes too large. Therefore, when the short fiber nonwoven web layer B is laminated on the web layer A and subjected to high-pressure liquid flow treatment, all the constituent fibers of the web layer A and the constituent fibers of the web layer B are used. Are not confounded enough in three dimensions,
The whole is not integrated, and neither is preferable.

Next, after laminating a web layer B composed of the short fibers on both surfaces of the obtained web layer A, the laminate is subjected to a high-pressure liquid flow treatment to form the fibers constituting the web layer A and the web layer. The constituent fibers of the web layer B are three-dimensionally entangled with the constituent fibers of the web layer B, and integrated as a whole. The web layer B to be laminated is a parallel card web, a random card web, a cross laid web, or the like made of the above-mentioned short fiber material, and the basis weight is preferably 10 to 100 g / m ² . In the present invention, as described above, the web layer B may be formed of a single material selected from the short fiber materials and a mixture of a plurality of types of materials. This web layer B is replaced with web layer A.
When laminating on both sides, the web layers B may be made of the same material, or may be made of different materials as necessary. When the high-pressure liquid flow treatment is performed, for example, the pore size is 0.05-2.
Injection holes of 0 mm, especially 0.1 to 0.4 mm, with a hole interval of 0.1 mm.
A method in which high-pressure liquid having an injection pressure of 5 to 150 kg / cm ² G is injected from the injection holes by using a large number of devices arranged in one or a plurality of rows of 3 to 10 mm. The arrangement of the injection holes is arranged in a row in a direction orthogonal to the traveling direction of the laminate. Generally, water or hot water is used as the high-pressure liquid. The distance between the injection hole and the laminate is 1
It is good to be about 15 cm. If this distance is less than 1 cm, the formation of the composite nonwoven fabric obtained by this treatment will be disturbed, while if this distance exceeds 15 cm, the impact force when the liquid stream collides with the laminate will decrease, resulting in three-dimensional confounding. Are not sufficiently performed, and both are not preferable.

In the present invention, the high-pressure liquid flow treatment is performed in two stages. First, as a first stage treatment, a high-pressure liquid stream having a pressure of 5 to 30 kg / cm ² G is jetted to collide with the laminate, and the constituent fibers of the web layer B are preliminarily entangled. In the treatment of the first stage, if the pressure of the liquid flow is less than 5 kg / cm ² G, the constituent fibers of the web layer B cannot be preliminarily entangled, while the pressure of the liquid flow is 30 kg / cm 2 ^{When the} pressure exceeds ² G, the constituent fibers of the web layer B are disturbed by the action of the liquid flow when the high-pressure liquid stream is jetted and collided with the laminate, and the formation of the web layer B is disturbed and the weight of the web layer is uneven. Absent.
Next, as the second stage processing, the pressure is 40 to 150 kg.
/ Cm ² G of high-pressure liquid flow is ejected to impinge on the laminate, so that the constituent fibers of the web layer A and the constituent fibers of the web layer B are three-dimensionally entangled with each other. The laminate is three-dimensionally entangled to integrate the laminate as a whole. If the pressure of the liquid stream is less than 40 kg / cm ² G in the treatment of the second stage, the above-mentioned three-dimensional confounding between the fibers cannot be sufficiently formed. If it exceeds 150 kg / cm ² G, the flexibility and bulkiness of the obtained composite nonwoven fabric are not improved,
Neither is preferred. In the present invention, a high-pressure liquid flow having a pressure of 40 to 150 kg / cm ² G is used as the second stage treatment. When the second stage treatment is performed on the laminate, the first stage treatment is performed as described above. Since the constituent fibers of the web layer B are preliminarily entangled with each other by the treatment at the stage, the constituent fibers of the web layer B are disturbed by the action of the liquid flow when the high-pressure treatment of the second stage is performed, and the web layer B
No irregularities in the formation and no spots are formed.
When the high-pressure liquid flow treatment is performed, the support material for supporting the laminate is, for example, a mesh screen such as a 20 to 100 mesh wire mesh or a perforated plate, as long as the high-pressure liquid flow can penetrate the laminate. Not limited.

After the high-pressure liquid flow treatment, excess moisture is removed from the laminate after the treatment. In removing the excess moisture, a known method can be employed. For example, the excess moisture is mechanically removed to some extent using a squeezing device such as a mangle roll, and the remaining moisture is subsequently removed using a drying device such as a continuous hot air drier to obtain a final composite nonwoven fabric product. This drying treatment may be a wet heat treatment as required in addition to the normal dry heat treatment.
Further, in selecting the processing conditions such as the drying temperature and the time in performing the drying processing, the conditions may be selected so as to allow not only the mere removal of water but also appropriate shrinkage.

[0017]

The composite nonwoven fabric obtained according to the present invention comprises a synthetic long-fiber non-woven web layer A, a short-fiber non-woven web layer B laminated on both sides, and a partial gap between the constituent fibers of the synthetic long-fiber non-woven web layer A. The constituent fibers of the synthetic long-fiber nonwoven web layer A and the constituent fibers of the short-fiber nonwoven web layer B are three-dimensionally entangled with each other, and are the constituent fibers of the short-fiber nonwoven web layer B They are three-dimensionally entangled and integrated as a whole. In the present invention, as the web layer A,
It has an area of 0.1 to 1.0 mm ² as a thermal pressure welding area,
The density, that is, the pressure contact density is 5 to 100 points / cm ^2, preferably 10 to 80 points / cm ² , and the ratio of the area of the entire heat-welded region to the total surface area of the web layer, that is, the contact area ratio is 5 to 50%, preferably Partial heat welding using a hot embossing roll having a temperature of 8 to 40% and a surface temperature of 50 to 80 ° C. lower than the melting point of the polymer having the lowest melting point in the web constituting fiber, with a roll linear pressure of 5 to 30 kg / cm. The long fiber web obtained by the treatment is used as a starting material. By the hot pressing process using a hot embossing roll having a lower temperature and a lower linear pressure than in the usual case, the constituent fibers of the long fiber web are once preliminarily hot pressed. Next, after laminating the web layer B on both sides of the long fiber web after the heat pressing treatment,
A high-pressure liquid flow treatment at a pressure of 5 to 30 kg / cm ² G is performed as a first-stage treatment, followed by a high-pressure liquid flow treatment at a pressure of 40 to 150 kg / cm ² G as a second-stage treatment. In the present invention, the pressure in the second stage is 40 to 1
By applying the high-pressure liquid flow treatment of 50 kg / cm ² G, the preliminary inter-fiber heat welding of the long fibers existing in the heat-welded region of the long fiber web after the heat-welding treatment is partially broken, and the long fibers are split. Although it is peeled, such partial destruction of the heat-welded area does not occur in the entire heat-welded area. That is, it has a conventional area of 0.1 to 1.0 mm ² , a press contact density of 5 to 100 points / cm ^2, preferably 10 to 80 points / cm ² , and a press contact area ratio of 5 to 50%, preferably 8 ４０40% of the heat-welded area is partially destroyed, and the density of the pressure contact is ² to 80 points / cm ^2, preferably 4 to 60 points / c.
m ² , ² to 30%, preferably 4 to 20%, in terms of the press contact area ratio, remains the heat press contact area. By using the long-fiber web which leaves such a specific heat-welded area as the web layer A, the dimensional stability is improved when the composite non-woven fabric is formed by the remaining heat-welded area. When the composite nonwoven fabric is formed by the existence of the region, the constituent fibers of the web layer A and the constituent fibers of the web layer B are sufficiently entangled with each other three-dimensionally and integrated as a whole.

[0018]

EXAMPLES Next, the present invention will be specifically described based on examples, but the present invention is not limited to these examples. In the examples, the measurement of each characteristic value was performed by the following method. Melting point (° C): Differential scanning calorimeter DS manufactured by PerkinElmer
Measured at a heating rate of 20 ° C / min using C-2 type,
The temperature at which an extreme value was obtained in the obtained melting endothermic curve was defined as the melting point. Melt index: Measured according to the method described in ASTM-D-1238 (E). The relative viscosity (a): the relative viscosity of the polyethylene terephthalate (A) was measured by the following methods. That is, a mixture of phenol and ethane tetrachloride was used as a solvent in an equal weight mixture, 0.5 g of a sample was dissolved in 100 cc of the solvent, and the measurement was carried out by a conventional method at a temperature of 20 ° C. The relative viscosity (b): a relative viscosity of polycapramide (nylon 6) (b) were measured by the following method. That is, 9
1 g of a sample was dissolved in 100 cc of 6% sulfuric acid, and the measurement was performed by a conventional method at a temperature of 25 ° C. Non-woven fabric weight (g / m ² ): 1 length from standard sample
After making a total of 10 sample pieces of 0 cm × 10 cm in width and reaching the equilibrium moisture, the weight (g) of each sample piece was weighed, and the average of the obtained values was calculated per unit area (m ² ). And converted to the basis weight (g / m ² ). Tensile strength (kg / 5 cm) and tensile elongation (%) of nonwoven fabric: Measured according to the method described in JIS-L-1096A. That is, the sample length is 10 cm and the sample width is 5 c
A total of 10 sample pieces of m were prepared, and the longitudinal direction of the non-woven fabric for each sample piece was measured using a constant-speed elongation type tensile tester (Tensilon UTM-4-1-100 manufactured by Toyo Baldwin Co., Ltd.).
The film was elongated at a tensile speed of 10 cm / min, and the average value of the obtained load values at cutting (kg / 5 cm) was calculated as the tensile strength (kg / 5 c).
m), the average value of the elongation at break (%) was defined as the tensile elongation (%). Area shrinkage (%): sample length 20 cm, sample width 20 c
A total of five sample pieces of m were prepared, and each sample piece was subjected to a heat treatment for 5 minutes using an air oven type heat treatment machine at a predetermined temperature. Then, using the area S1 ( cm ² ) value of the sample piece before the heat treatment and the area S2 ( cm ² ) value of the sample piece after the heat treatment,
The average value of the shrinkage rates (%) calculated according to the following equation (a) was defined as the area shrinkage rate (%). Area shrinkage (%) = [1- (S2 / S1)]. Times.100 (b) Compression stiffness (g): sample length 10 cm, sample width 5 cm
A total of five specimens were prepared, and each specimen was bent in the transverse direction to form a cylindrical body, and the end of each cylinder was joined to obtain a compression-hardness measurement sample. Next, each measurement sample was compressed in the axial direction thereof at a compression rate of 5 cm / min using a constant-speed elongation type tensile tester (Tensilon UTM-4-1-100 manufactured by Toyo Baldwin Co., Ltd.). The average value of the load values (g) was taken as the compression stiffness (g). Delamination strength ( g / 5cm ): A total of three sample pieces with a sample length of 15cm and a sample width of 5cm were prepared, and a constant-speed elongation type tensile tester (Toyo Baldwin Web layer B at a tensile speed of 10 cm / min using Tensilon UTM-4-1-100 manufactured by
From the end of the non-woven fabric to a position 5 cm from the end of the non-woven fabric, and the average value of the obtained load values (g / 5 cm) was defined as the delamination strength ( g / 5 cm 3 ).

Example 1 A long fiber nonwoven web layer A was produced by a spunbond method using a polyethylene terephthalate polymer chip having a melting point of 259 ° C. and a relative viscosity (a) of 1.38. That is,
The polymer chip was melted, melted and spun through a spinning hole at a spinning temperature of 290 ° C., and the melted and spun polymer stream was cooled and then taken off at 4800 m / min using an air sucker. Then, the fiber is opened using a corona discharge means, collected and deposited on a moving collecting surface to form a web having a single-fiber fineness of 3.0 denier, and then heat-welded to the obtained web. To give a weight of 30g
/ M ² of web layer A was obtained. In performing the heat-pressing treatment, an embossing roll in which an engraved pattern having an area of 0.6 mm ² was disposed at a press-contact density of 20 points / cm ² and a press-contact area ratio of 15%, and a metal roll having a smooth surface were used. . The surface temperature of the embossing roll and the metal roll having a smooth surface is set to 200.
° C and the linear pressure between both rolls was 10 kg / cm. Separately, using a short fiber cotton having a single fiber fineness of 2.0 denier and a fiber length of 51 mm made of a polyethylene terephthalate polymer, a parallel card machine was used to produce a parallel card web layer B having a basis weight of 15 g / m ² . Next, a web layer B was laminated on both sides of the obtained web layer A, and the obtained laminate was placed on a 30-mesh wire net moving at a moving speed of 30 m / min, and subjected to a high-pressure liquid flow treatment. In the high-pressure liquid flow treatment, the injection hole with a hole diameter of 0.12 mm has a hole interval of 0.62 mm.
Using a high-pressure columnar water flow treatment device arranged in three groups
A columnar water flow was applied in two stages from a position 80 mm above the laminate. In the first stage processing, the pressure is 20 kg /
cm ² G and the pressure in the second stage treatment was 60 kg / c
m ² G. In addition, the process of the 2nd stage was performed once each from the front and back of the laminate. Next, after removing excess moisture from the obtained treated laminate using a mangle roll, the laminate was subjected to a drying treatment at a temperature of 98 ° C. using a hot air drier to obtain a composite nonwoven fabric. The composite nonwoven fabric obtained above is
The basis weight is 60 g / m ² , the tensile strength is 48 kg / 5 cm,
The tensile elongation is 54%, the area shrinkage at the treatment temperature of 160 ° C is 2.1%, the mechanical properties and dimensional stability are excellent, the delamination strength is 320g / 5cm, and the delamination resistance is high enough. And the flexibility was 34 g and the flexibility was excellent.

Example 2 As the web layer B, a parallel card web made of cotton bleached cotton having an average fiber length of 22 mm and having a basis weight of 15 g / m ² was used.
A composite nonwoven fabric was obtained in the same manner as in Example 1 except that g / cm ² G was used. The composite nonwoven fabric obtained above had a basis weight of 60 g / m ² , a tensile strength of 30 kg / 5 cm, a tensile elongation of 45%, and an area shrinkage of 1.2 at a treatment temperature of 160 ° C.
%, Excellent in mechanical properties and dimensional stability, delamination strength is 360 g / 5 cm, delamination resistance is high and fully integrated, and compression flexibility is 45 g and flexibility is excellent. Was.

EXAMPLE 3 A polyethylene terephthalate polymer chip having a melting point of 259 ° C. and a relative viscosity (a) of 1.38 and a polyethylene polymer chip having a melting point of 132 ° C. and a melt index of 20 g / 10 min were spunbonded. A composite long fiber nonwoven web layer A was produced by the method. That is, the two polymer chips were melted, and the spinning temperature of the polyethylene terephthalate polymer was 290 ° C. and the spinning temperature of the polyethylene polymer was 250 ° C.
Melt spinning through the composite spinning hole so that the polyethylene terephthalate polymer is disposed at the core and the polyethylene polymer is disposed at the sheath, and the melt-spun polymer stream is cooled and then taken up using an air filter. Speed 4500
m / min, open using corona discharge means,
It is collected and deposited on a moving collecting surface, and the polyethylene terephthalate polymer is disposed in the core and the polyethylene polymer is disposed in the sheath, the composite ratio is 1/1, and the single fiber fineness is 3. The web is made of 0 denier composite filament,
Next, the obtained web is subjected to a heat-pressure treatment to obtain a basis weight of 3
A web layer A of 0 g / m ² was obtained. Thermocompression bonding process during the performing the engraving pattern pressure point area 0.6 mm ² Density 2
An embossing roll provided at 0 points / cm ² and a pressing area ratio of 15% and a metal roll having a smooth surface were used. The surface temperature of the embossing roll and the metal roll having a smooth surface is set to 8
The temperature was 5 ° C. and the linear pressure between both rolls was 10 kg / cm.
Next, the same web layer B as that used in Example 1 was laminated on both sides of the obtained web layer A, and the obtained laminate was placed on a wire mesh. After the water flow treatment, the excess water was removed and dried to obtain a composite nonwoven fabric. The composite nonwoven fabric obtained above has a basis weight of 6
0 g / m ² , tensile strength 25 kg / 5 cm, tensile elongation 43%, area shrinkage at processing temperature 110 ° C. 1.1%
It was excellent in mechanical properties and dimensional stability, had a delamination strength of 320 g / 5 cm, had high delamination resistance, and was sufficiently integrated, and had a compression stiffness of 28 g and excellent flexibility. .

Example 4 The web layer B is made of short fiber cotton having a single fiber fineness of 2.0 denier and a fiber length of 51 mm made of a polycapramide (nylon 6) polymer having a relative viscosity (b) of 2.61. Was obtained in the same manner as in Example 3 except that a parallel card web of 15 g / m ² was used. The composite nonwoven fabric obtained above had a basis weight of 60 g / m ² , a tensile strength of 47 kg / 5 cm, a tensile elongation of 63%, and an area shrinkage at a treatment temperature of 110 ° C. of 0.8%. Excellent properties and dimensional stability, 290 g / 5c delamination strength
m, the resin had high delamination resistance and was sufficiently integrated, and had a compression stiffness of 22 g and excellent flexibility.

Comparative Example 1 The same procedure as in Example 1 was carried out except that the surface temperature of the embossing roll and the metal roll having a smooth surface were 245 ° C. and the linear pressure between the two rolls was 50 kg / cm. Thus, a web layer A was manufactured. Next, the same web layer B as that used in Example 1 was laminated on both sides of the obtained web layer A, and the obtained laminate was placed on a wire mesh. After the water flow treatment, the excess water was removed and dried to obtain a composite nonwoven fabric. The composite nonwoven fabric obtained above has a basis weight of 60 g / m ² and a tensile strength of 1
8kg / 5cm, tensile elongation 35%, processing temperature 160
The area shrinkage at ℃ is 4.8%, and the delamination strength is 15 g /
5 cm and compression bristles were 114 g. As is clear from the above characteristic values, this composite nonwoven fabric has a high thermal pressure treatment temperature and a strong partial thermal pressure welding of the web layer A. The existing constituent fibers of the web layer A do not separate and separate, that is, the constituent fibers and the constituent fibers of the web layer B are not sufficiently three-dimensionally entangled with each other, so that the mechanical properties are inferior. Because of insufficient properties, the delamination resistance was not improved.

Comparative Example 1 The basis weight was set to 3 on only one side of the web layer A used in Example 1.
The same web layer B as that used in Example 1 was laminated except that it was 0 g / m ² , the obtained laminate was placed on a wire mesh, and the pressure of the second stage high pressure columnar water treatment was 50 kg. / C
A composite nonwoven fabric was obtained in the same manner as in Example 1 except that m ² G was used. The composite nonwoven fabric obtained above has a basis weight of 60 g.
/ M ² , tensile strength 23 kg / 5 cm, tensile elongation 62
%, The area shrinkage at a treatment temperature of 160 ° C. was 3.4%, the delamination strength was 290 g / 5 cm, and the compression stiffness was 22 g. In this composite nonwoven fabric, the constituent fibers of the web layer A and the constituent fibers of the web layer B are three-dimensionally entangled with each other when subjected to a high-pressure columnar water flow treatment, so that mechanical properties and delamination resistance are practical problems. Although the surface layer was not present, the constituent fibers were not sufficiently entangled on the surface of the other surface where the web layer A was exposed, so that the abrasion resistance was poor.

[0025]

The composite nonwoven fabric obtained by the present invention comprises a synthetic long fiber nonwoven web layer A and a short fiber nonwoven web layer B on both sides.
Are laminated, and the constituent fibers of the synthetic long-fiber nonwoven web layer A are partially hot-pressed to each other.
And the constituent fibers of the short-fiber non-woven web layer B are three-dimensionally entangled with each other, and the constituent fibers of the short-fiber non-woven web layer B are three-dimensionally entangled with each other to be integrated as a whole. It has excellent mechanical properties, dimensional stability and flexibility, and is suitable not only for industrial materials but also for general materials. Further, according to the method for producing a composite nonwoven fabric of the present invention, the nonwoven fabric can be produced efficiently.

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) D04H 1/00-18/00

Claims (1)

(57) [Claims] 1. A hot embossing roll having a surface temperature of 50 to 80 ° C. lower than the melting point of a polymer having the lowest melting point among the constituent fibers of a synthetic long-fiber nonwoven web formed by a spunbond method. Pressure 5-30kg / cm
To form a synthetic long-fiber nonwoven web layer A, and then to obtain a synthetic long-fiber nonwoven web layer A
After laminating the short fiber non-woven web layer B on both sides of the web, a high-pressure liquid flow treatment at a pressure of 5 to 30 kg / cm ² G is performed as a first stage treatment to separate the constituent fibers of the short fiber non-woven web layer B from each other. Preliminarily entangled and subsequently subjected to a high-pressure liquid flow treatment at a pressure of 40 to 150 kg / cm ² G as a second stage treatment to form the constituent fibers of the synthetic long-fiber nonwoven web layer A and the short-fiber nonwoven web layer B. A method for producing a composite nonwoven fabric, comprising three-dimensionally entanglement of constituent fibers with each other, and three-dimensionally entanglement of constituent fibers of the short fiber nonwoven web layer B, and integrating them as a whole.