JP3785034B2 - Support for forming non-woven fabric with embroidery and method for producing non-woven fabric with embroidery pattern using the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a nonwoven fabric-forming support for forming a patterned nonwoven fabric and a method for producing a patterned nonwoven fabric.
[0002]
[Prior art]
BACKGROUND ART Nonwoven fabric forming supports for patterning a nonwoven fabric surface are conventionally known. A typical example is a support for forming a perforated nonwoven fabric. For example, Japanese Patent Laid-Open No. 62-69867 discloses a support for manufacturing a perforated nonwoven fabric having a large number of hemispherical protrusions having small through holes. Is disclosed. In addition, as a method for forming a design pattern on a nonwoven fabric surface, Japanese Patent Laid-Open No. 4-327255 discloses that a thermoplastic resin protrusion is thermally welded to the molding side surface of a nonwoven fabric manufacturing belt body, and various characters such as letters are applied to the nonwoven fabric surface. A belt for manufacturing a nonwoven fabric that forms a design pattern (by a concavo-convex pattern or an aperture pattern) is disclosed.
[0003]
[Problems to be solved by the invention]
However, the conventional support for performing patterning molding on these conventional nonwoven fabrics has the following disadvantages. For example, in the support for producing apertured nonwoven fabric described in JP-A-62-69867, it is convenient to regularly and clearly form a circular or elliptical aperture pattern on the nonwoven fabric surface. It was difficult to give an arbitrary design pattern to the surface. Further, the support according to the invention described in the publication requires the formation of projections having the plurality of small through holes on a cylinder surface (or a flat plate surface) having a required diameter and length, and such a cylinder (or The flat plate) is difficult to process wide due to processing problems, and there is a limit to the provision of aperture patterns for wide nonwoven fabric applications. Furthermore, for example, if some of the protrusions are damaged due to some trouble, it is difficult to repair them, and it is necessary to replace the entire support. It had economic problems such as bulkiness. Moreover, the nonwoven fabric manufacturing belt described in JP-A-4-327255 is convenient for easily and economically imparting various design patterns such as letters on the nonwoven fabric surface, and also supports wide nonwoven fabric applications. It is possible to provide a clear uneven pattern according to the height difference and shape of the protrusions, especially when forming a nonwoven fabric by the air-through method, but when forming a nonwoven fabric by the water jet method, Since the object is fixed, the fiber assembly at the upper part of the protrusion is caused to flow to the periphery of the protrusion by the jet pressure of the high-pressure water flow. As a result, the nonwoven fabric surface corresponding to the protrusion part installed on the belt surface Openings without fibers are formed, and design patterns of various shapes are formed by arranging and combining the formed openings. Therefore, the design pattern formed is unsuitable for providing a relatively small or complex design pattern. Further, even if a relatively small and complicatedly designed protrusion is previously welded to the belt so as to give a relatively small and complicated design pattern, the fibers on the upper part of the protrusion are caused by the jet pressure of the high-pressure water flow around the protrusion. As a result, the entire surface of the projecting portion forms an opening pattern in which no fiber is present. As a result, the design pattern portion is easily deformed with a slight tension, and the tensile strength of the entire nonwoven fabric is lowered. It was.
[0004]
In order to solve the above problems, the present invention is difficult to lose shape on the nonwoven fabric surface, and the tensile strength of the entire nonwoven fabric can be maintained, and a design pattern of any size, form, and shape can be formed on the nonwoven fabric surface of any width dimension. Furthermore, an object of the present invention is to provide a support for forming a patterned nonwoven fabric that is economically inexpensive. Moreover, the manufacturing method of the nonwoven fabric with an embroidery pattern using this is provided.
[0005]
[Means for Solving the Problems]
The present inventors controlled the behavior of the fiber assembly accompanying the high-pressure water flow of the fiber web placed on the support with the support for forming the nonwoven fabric, and formed a large opening pattern on the nonwoven fabric surface with an arbitrary design pattern. In order to form without forming, it has been found that this can be achieved by embroidering the support with a monofilament, and the present invention has been achieved. That is, the present invention is a nonwoven fabric forming support used in a nonwoven fabric forming apparatus for forming a nonwoven fabric by supporting and transporting a fiber web, and embroidery is applied to at least a part of the surface of the nonwoven fabric forming support. An embroidered nonwoven fabric forming support characterized in that the nonwoven fabric forming support is made of a mesh-like woven fabric, and one or a plurality of monofilaments are pierced as embroidery thread into the woven fabric, or An embroidered nonwoven fabric forming support body, which is knitted and the embroidery thread forms a three-dimensional design portion on the fabric surface. The embroidery thread preferably forms a floating loop structure with respect to the mesh-like fabric surface. Further, the height H (mm) of the three-dimensional design portion formed by the embroidery thread is 0.2 ≦ H ≦ 9.0, and the width diameter W (mm) of the embroidery thread is 0.2 ≦ W. It is preferable that ≦ 4.0. Moreover, it is preferable that the terminal part of the embroidery thread is located on the back surface and / or the surface of the mesh-like woven fabric, and the terminal part is subjected to a thread omission prevention treatment.
[0006]
In another aspect of the present invention, one or a plurality of monofilament embroidery threads are inserted or knitted into a nonwoven fabric forming support made of a mesh woven fabric, and the embroidery thread floats on the surface of the support to form a loop structure. A pre-entangled fiber entangled web is placed on and transported to the embroidery nonwoven fabric forming support on which the three-dimensional design part to be presented is formed, and a high-pressure water stream is sprayed from above the fiber entangled web to contact the three-dimensional design part. A method for producing a nonwoven fabric with an embroidery pattern, characterized in that an embroidery pattern is formed on the nonwoven fabric surface, wherein the nonwoven fabric with an embroidery pattern is formed by a knuckle portion formed by a longitudinal parallel wire of a mesh-like fabric The embroidery pattern portion is formed by a three-dimensional design portion having a floating loop structure and the embroidery pattern portion forms a recess with respect to the nonwoven fabric surface, and the bottom surface of the recess is complex. It is preferable that the have been formed by the opening and the bridge-like fiber aggregate. The embroidery pattern is preferably composed of an embroidery pattern portion formed in contact with the three-dimensional design portion and a blur pattern portion formed around the embroidery pattern portion. The present invention solves the above problems by using such a support for forming an embroidery nonwoven fabric and a method for producing an embroidery nonwoven fabric using the same.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below in detail with reference to the drawings of the examples. FIG. 1 is a perspective view showing a part of a support for forming an embroidered nonwoven fabric according to the present invention. FIG. 2 is an enlarged plan view of a part A including the three-dimensional design part (3) of FIG. 3 is a cross-sectional view taken along the line BB for explaining the floating loop structure (5) of FIG. FIG. 4 is a simplified diagram for explaining a water-jet non-woven fabric forming apparatus. FIG. 5 is a plan photograph of the embroidery pattern portion of the nonwoven fabric with an embroidery pattern formed in contact with the three-dimensional design portion.
[0008]
The embroidered nonwoven fabric forming support (1) of the present invention is a support characterized in that at least a part of the surface of the mesh fabric (2) is embroidered, as illustrated in FIGS. is there. By embroidering, an arbitrary three-dimensional design portion (3) can be formed on the surface of the support, and the fiber entangled web (10) preliminarily entangled as illustrated in FIG. An embroidery-patterned nonwoven fabric (12) having an embroidery pattern formed by jetting the water stream (11) is obtained. The nonwoven fabric-forming support may be a wire mesh, a punching cylinder, or the like, but a plastic fabric such as polyester or nylon is preferable in consideration of ease of embroidery, shape retention of the embroidery portion, and maintenance. Further, the support is preferably a mesh-like woven fabric having a void portion to which the embroidery thread (4) is inserted or knitted for embroidering. Further, the embroidery thread is not particularly limited, but a metal filament or a synthetic resin monofilament is preferable as a fiber having a surface form in which the fiber is not easily entangled with the embroidery thread when the fiber web is entangled. When a metal wire is used for the mesh fabric or the embroidery thread, its weight is heavy, and there is a concern about breakage due to metal fatigue, generation of rust, and the like. In view of having an appropriate bending rigidity, the plastic monofilament is more preferable. The embroidery thread (4) may be one or plural and may be appropriately selected according to the number of meshes of the support, the woven structure, and the embroidery pattern.
[0009]
In the present invention, the embroidery thread (4) preferably forms a floating loop structure (5) with respect to the fabric surface. Even if the embroidery thread is in close contact with the surface of the support, it is possible to form the embroidery pattern on the nonwoven fabric surface, but it is preferable to have a floating loop structure in order to give a clearer embroidery pattern. With the floating loop structure, a floating loop is formed by the embroidery thread except for the contact point between the fabric and the embroidery thread, and a space (6) is formed between the surface of the fabric. Since the fiber assembly located on the floating loop has such a structure, even if a high-pressure water flow is blown from above, the space (6) ensures the escape of the water flow, and the embroidery thread forms the floating loop. Since the embroidery thread is made of plastic monofilament with appropriate bending rigidity, the floating loop part slightly swings when subjected to the jet pressure of high-pressure water flow, and the fiber assembly is It is possible to relieve the behavior of a fiber that attempts to form a hole pattern in which the water flow pressure is received straight and the fiber is flowed to other than the loop portion. As a result of these actions, the fiber assembly located on the floating loop is secured even though it is affected by the high-pressure water flow, so the entire embroidery pattern corresponding to the three-dimensional design part formed by embroidery forms an opening. Without embedding, the non-woven fabric surface can be embroidered while leaving the bridge-like fiber assembly to some extent.
[0010]
As described above, the present invention controls the behavior of the fiber assembly on the three-dimensional design portion by embroidery, and the height H (mm) of the three-dimensional design portion is 0.2 ≦ H ≦ 9.0. The width W (mm) of the embroidery thread is preferably 0.2 ≦ W ≦ 4.0. By setting the height H and the width W as described above, an aperture pattern ground portion formed by a knuckle portion (31) formed of a longitudinal weft wire of a mesh woven fabric as illustrated in FIGS. The embroidery pattern portion (20) formed by the three-dimensional design portion having a floating loop structure can be formed, the embroidery pattern portion forms a recess (20a) with respect to the nonwoven fabric surface, and a plurality of bottom surfaces of the recess are formed. A non-woven fabric with an embroidery pattern formed by the hole portion (20b) and the bridge-like fiber assembly (20c) is obtained. Moreover, a non-woven fabric with an embroidery pattern comprising an embroidery pattern portion formed by contacting the embroidery pattern with the three-dimensional design portion and a blur pattern portion (22) formed around the embroidery pattern portion is obtained. This blurring pattern is judged to be formed by a combination of the above-described delicate swinging movement of the floating loop portion and a change in the injection direction of the high-pressure water flow blocked by the floating loop portion, but the blurring pattern is formed. As a result, the embroidery pattern itself can make the user feel light and soft, and an unprecedented pattern can be expressed. If the height H (mm) of the three-dimensional design is H <0.2 and the width W (mm) of the embroidery thread is W <0.2, a plurality of openings or bridges on the recess itself or the bottom surface of the recess It becomes difficult to form a fiber-like fiber aggregate, and as a result, the expression of the embroidery pattern itself is poor. The same applies to the case where the height H (mm) of the three-dimensional design is H> 9.0 and the width W (mm) of the embroidery thread is W> 4.0. If the height H (mm) of the three-dimensional design is H> 9.0, the degree of freedom of the floating loop part becomes too high, and the space part becomes too large, and the control of the behavior of the fiber assembly on the floating loop is made. Becomes difficult, and at the same time, wrinkles easily occur on the nonwoven fabric surface. Further, if the width W (mm) of the embroidery thread is W> 4.0, it becomes easy to receive the jet pressure of the high-pressure water flow by the floating loop straight, and it becomes easy to form the opening portion of the entire embroidery pattern. Complex embroidery is difficult to apply. More preferably, the height H (mm) of the three-dimensional design is 0.7 ≦ H ≦ 7.0, and the width W (mm) of the embroidery thread is 0.3 ≦ W ≦ 2.0.
[0011]
Moreover, it is preferable that the terminal part of the embroidery thread is located on the back surface and / or the front surface of the mesh-like woven fabric, and the terminal part is subjected to a thread omission prevention treatment. This is because if the end portion is not subjected to the thread omission prevention treatment, the embroidery pattern is broken, the floating loop structure cannot be maintained, and inconvenience occurs in the formation of the nonwoven fabric with the embroidery pattern. The thread drop prevention treatment not only prevents the thread from coming out of the embroidery thread, but also has the purpose of preventing the floating loop structure of the three-dimensional design part from being deformed by the jet pressure of the high-pressure water flow, and supports the three-dimensional design part. It is also a process of firmly fixing to the body surface. Examples of the thread omission prevention process include a process of connecting the both ends of the embroidery thread to each other, a process of forming a knot at each end, a process of fixing to a fastener other than the embroidery thread, and heat melting each end to illustrate in FIG. As described above, it is possible to appropriately employ a method in which the end portion of the embroidery thread is thermally deformed into a countersunk screw shape on the back surface of the plastic fabric. What is necessary is just to select suitably according to what form the support body of this invention is used. For example, in the case of fixing to the surface of the cylinder (15) in FIG. 4, it is preferable to tie both ends of the embroidery thread on the back of the support, and the belt is stretched between the support rollers (16) in FIG. In this case, in order to prevent the belt running from being hindered, in the case of the treatment on the surface of the support or the treatment on the back surface, the above-mentioned countersunk heat deformation treatment is preferable.
[0012]
Further, one or a plurality of embroidery threads are inserted or knitted into a nonwoven fabric forming support made of a mesh-like woven fabric, and the three-dimensional design portion in which the embroidery threads float and have a loop structure is formed on the support surface. A pre-entangled fiber entangled web is placed on and transported to an embroidered nonwoven fabric forming support, and a high-pressure water stream is sprayed from above the fiber entangled web to form a design pattern corresponding to the three-dimensional design on the nonwoven fabric surface. Is preferred. The pre-entanglement here is a process for making the fiber aggregate on the floating loop less susceptible to the influence of the high-pressure water flow. For example, by preliminarily performing the water-entanglement treatment on the card lifting web in advance, This is intended to limit the behavior of the fiber assembly, and is preferable in inhibiting the formation of the open portion in the entire three-dimensional design portion.
[0013]
The present invention has been described above based on the illustrated embodiments. However, the present invention is not limited to such embodiments, and various modifications may be made to the specific structure within the scope of the present invention. Needless to say.
[0014]
【Example】
The present invention will be described more specifically with reference to the following examples and comparative examples, including the parts described in the above embodiments.
[0015]
Example 1 Using a known spunlace nonwoven fabric forming apparatus shown in FIG. 4, a card-lifted fiber web having a weight of 40 g / m ² with 100% rayon is applied to a 90-mesh mesh plastic fabric with a water pressure of 3 MPa and a conveying speed. A support for forming an embroidered nonwoven fabric as described above with reference to FIGS. 1 to 3 in which a water entangled web (10) subjected to water jet entanglement treatment at 4 m / min and a pre-entangled fiber entangled web (10) is tightly fixed to the circumferential surface of an opening cylinder (15) ( 1) The spunlace nonwoven fabric with an embroidery pattern (12) shown in FIG. 5 and FIG. 6 was obtained by conducting water entanglement treatment at a water pressure of 3 MPa and a conveying speed of 4 m / min from above the fiber entangled web. . The embroidered nonwoven fabric forming support body is made of a mesh-like plastic fabric woven from warp and weft yarns of polyester monofilaments having a wire diameter of 0, 5 mmΦ into 16 × 16 mesh in length and width, and the surface of the plastic fabric is shown in FIGS. A plurality of petal-shaped embroidery with a diameter of about 25 mm is used. As the embroidery thread, one polyester monofilament with a wire diameter of 0.6 mmΦ is used. The end portion is heat-treated into a dish screw shape. By the embroidery, a three-dimensional design portion having a petal-like floating loop structure as illustrated is formed on the surface of the plastic fabric, the height H of the three-dimensional design portion is 5 mm, and the width of the embroidery thread W is a support for forming an embroidered nonwoven fabric having a thickness of 0.6 mm. The obtained non-woven fabric (12) with an embroidery pattern is a perforated pattern ground portion (21) formed by a knuckle portion (31) formed of a longitudinal weft wire of the mesh-like woven fabric as shown in FIGS. An embroidery pattern portion (20) formed by a three-dimensional design portion having a floating loop structure is formed, the embroidery pattern portion forms a recess (20a) with respect to the nonwoven fabric surface, and the bottom surface of the recess has a plurality of openings. The part (20b) and the bridge-like fiber assembly (20c) were formed. In addition, a blur pattern (22) appeared around the embroidery pattern portion, and a petal-like embroidery pattern that gave a soft and soft impression was formed. A sample (length direction dimension 10 cm, width direction dimension 5 cm) in which the embroidery pattern portion was placed in the center of the obtained nonwoven fabric with embroidery pattern was prepared, and the tensile strength in the length direction was measured (Tensilon tensile strength test The tensile strength was 37.6 (N / 50 mm). For reference, only the portion without the embroidery pattern was measured in the same manner. The tensile strength was 28.8 (N / 50 mm), and it was confirmed that the strength of the whole nonwoven fabric was improved by applying the embroidery pattern. This is considered to have contributed to the improvement of tensile strength by rearrangement of the fiber assembly constituting the embroidery pattern portion.
[0016]
(Example 2) A spunlace nonwoven fabric with an embroidery pattern was obtained in the same manner as in Example 1 except that the embroidery portion did not have a floating loop structure. Although not illustrated on the obtained nonwoven fabric surface, a petal-like embroidery pattern was confirmed in the same manner, but it was not as clear as the embroidery pattern obtained in Example 1. Similarly, when the tensile strength test was performed, it was 28.4 (N / 50 mm). This is due to the presence or absence of a floating loop structure, which is the difference between Example 1 and Example 2, that is, the three-dimensional design part height H is only 0.6 mm, which is the wire diameter of the embroidery thread, resulting in a non-woven fabric surface. This is considered to be due to the fact that the influence of the high-pressure water flow on the three-dimensional design portion that abuts is low, affects the expression of the embroidery pattern, and the degree of rearrangement of the fiber assembly at the embroidery pattern portion is reduced.
[0017]
(Comparative Example 1) Although not shown, Example 3 is the same as Example 1 except that a three-dimensional design portion in Example 1 was processed into a flat petal shape with a rubber plate having a thickness of 5 mm and adhered and fixed to the surface of the mesh-shaped plastic fabric. A spunlace nonwoven fabric with a petal-like pattern using a rubber plate was obtained. In the obtained nonwoven fabric, a portion corresponding to a flat petal-like rubber plate body formed a large opening, and a pattern that could be distinguished from a slightly deformed petal shape was formed. Similarly, when the tensile strength test was performed, it was 23.2 (N / 50 mm), and a decrease in tensile strength was confirmed.
[0018]
【The invention's effect】
Since the support for forming an embroidered nonwoven fabric according to the present invention embroiders the surface of the support, any design pattern having an arbitrary size and an arbitrary width can be applied to the nonwoven fabric surface having an arbitrary width. In addition, when embroidering, it is possible to apply an embroidery pattern as appropriate on the existing mesh fabric surface, and even if the embroidery part is damaged for some reason, only that part can be repaired easily and economical nonwoven fabric It becomes a forming support. Further, by controlling the behavior of the fiber aggregate on the floating loop by adopting a floating loop structure, it is possible to develop an embroidered pattern having a soft soft feeling that is not found in conventional nonwoven fabric patterns, and there is no decrease in tensile strength of the nonwoven fabric itself Can be a forming support.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a part of a support for forming an embroidered nonwoven fabric according to the present invention.
FIG. 2 is an enlarged plan view of a part A in FIG.
3 is a cross-sectional view taken along a line BB in FIG.
FIG. 4 is a simplified view for explaining a nonwoven fabric forming apparatus using a water jet method.
FIG. 5 is a plane photograph for explaining an opening pattern ground part and an embroidery pattern part of a nonwoven fabric with an embroidery pattern formed in contact with a three-dimensional design part.
6 is an enlarged plan view of the embroidery pattern portion of FIG. 5. FIG.
FIG. 7 is a schematic cross-sectional view taken along the line CC in FIG. 6 for illustrating the shape of a recess in the nonwoven fabric with an embroidery pattern.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Support body for embroidered nonwoven fabric 2 Mesh-shaped plastic fabric 3 Solid design part 4 Embroidery thread 5 Floating loop structure 6 Space part 7 Thread removal prevention part 8 Embroidery thread end part 9 Card lifting web 10 Fiber entanglement web 11 High-pressure water flow 12 Nonwoven fabric with embroidery pattern 13 Nozzle 14 Suction means 15 Cylinder 16 Support roller 17 Feed roller 20 Embroidery pattern portion 20a Recess 20b Recess bottom surface opening 20c Recess bottom surface bridge-like fiber aggregate 21 Open hole pattern ground portion 21a Opening of ground portion Hole 22 Blurred pattern 30a Warp 30b Weft 31 Knuckle

Claims (8)

A non-woven fabric forming support for use in a non-woven fabric forming apparatus for forming a non-woven fabric by supporting and transporting a fiber web, wherein at least a part of the non-woven fabric forming support surface is embroidered. A support for forming non-woven fabric with embroidery. The nonwoven fabric-forming support is made of a mesh-like woven fabric, and one or a plurality of monofilaments are inserted or knitted into the woven fabric as embroidery threads, and the embroidery threads form a three-dimensional design on the surface of the woven fabric. The support for forming an embroidered nonwoven fabric according to claim 1. The support for forming an embroidery nonwoven fabric according to claim 2, wherein the embroidery thread forms a floating loop structure with respect to the mesh-like fabric surface. The height H (mm) of the three-dimensional design portion formed by the embroidery thread is 0.2 ≦ H ≦ 9.0, and the width W (mm) of the embroidery thread is 0.2 ≦ W ≦ 4. The support for forming an embroidered nonwoven fabric according to claim 2, wherein the support is 0. The embroidery nonwoven fabric according to any one of claims 2 to 4, wherein an end portion of the embroidery thread is located on the back surface and / or the front surface of the mesh-like woven fabric, and the end portion is treated to prevent the thread from coming off. Forming support. An embroidered nonwoven fabric in which one or a plurality of embroidery threads are inserted or knitted into a nonwoven fabric forming support made of a mesh woven fabric, and the embroidery thread is floated on the surface of the support to form a three-dimensional design. While placing and transporting the pre-entangled fiber entangled web on the forming support, spraying a high-pressure water stream from above the fiber entangled web to form an embroidery pattern on the nonwoven fabric surface in contact with the three-dimensional design portion A method for producing a non-woven fabric with an embroidery pattern. The non-woven fabric with an embroidery pattern is composed of an open pattern ground portion formed by a knuckle portion formed of a longitudinal parallel wire of a mesh-like woven fabric and an embroidery pattern portion formed by a three-dimensional design portion having a floating loop structure. The nonwoven fabric with an embroidery pattern according to claim 6, wherein the pattern portion forms a recess with respect to the nonwoven fabric surface, and the bottom surface of the recess is formed by a plurality of apertures and a bridge-like fiber assembly. Production method. 8. The nonwoven fabric with an embroidery pattern according to claim 6 or 7, wherein the embroidery pattern comprises an embroidery pattern portion formed in contact with the three-dimensional design portion and a blur pattern portion formed around the embroidery pattern portion. Production method.

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