3D fabric

Abstract

By optimizing the blending ratio of raw material fibers, basis weight, and three-dimensional surface pattern structure, a three-dimensional fabric is provided that is high-density, thick, and has a significantly increased water retention capacity. [Solution] The three-dimensional fabric 1 is composed of a nonwoven fabric 2 containing 75-85% by mass of rayon fiber and 15-25% by mass of polyester fiber, totaling 100% by mass, and having a basis weight of 90-120 g / m2, and multiple convex portions 4 are formed in a grid pattern on the surface of the nonwoven fabric.

Description

[Technical Field]

[0001] This invention relates to a three-dimensional fabric made of nonwoven fabric, and in particular to a three-dimensional nonwoven fabric that is high-density, thick, has low pressure loss, and has excellent water retention, and is applicable to nursing care, hygiene, and disaster prevention applications. [Background technology]

[0002] BACKGROUND ART Nonwoven fabrics containing rayon, polyester, etc. have hitherto been widely used for disposable hand towels, body towels, emergency preparedness towels, sanitary napkins, and baby wipes.

[0003] However, many conventional nonwoven fabrics have a flat shape, and have problems such as a lack of three-dimensionality, low water retention, insufficient thickness retention when wet, and insufficient wipeability after use.

[0004] In particular, in areas such as food service, nursing care, medical care, and disaster prevention, there has been a demand for nonwoven fabrics that meet high levels of thickness, strength, water retention, and three-dimensionality.

[0005] To solve these problems, spunlace processing techniques have been proposed in the past, for example in Patent Document 1 (JP 2010-144281 A), but these techniques still lack the "thickness," "high water retention," and "three-dimensional shape retention." [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-144281 DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0007] In contrast to the above-mentioned conventional techniques, the present invention aims to provide a three-dimensional fabric that is high-density, thick, and has significantly increased water retention capacity by optimizing the blending ratio of raw fiber, basis weight, and surface three-dimensional pattern structure.

[0008] In particular, the present invention provides a fabric that has lattice-shaped convex portions, retains its three-dimensional shape even when compressed or wetted, and provides a soft feel and strong wiping ability when in use. [Means for solving the problem]

[0009] In order to achieve the above object, the present invention It contains 75-85% by mass of rayon fiber and 15-25% by mass of polyester fiber, totaling 100% by mass, and has a basis weight of 90-120 g / m 2 It is made of nonwoven fabric, a plurality of convex portions formed in a grid pattern on the surface of the nonwoven fabric; To provide a three-dimensional fabric characterized by the above.

[0010] The three-dimensional fabric of the present invention having such a configuration imparts a high thickness and three-dimensional feel to the entire fabric, dramatically improving its water retention and wiping performance.

[0011] According to the three-dimensional fabric of the present invention, The vertical and horizontal widths of the convex portions are each 2.5 to 5.0 mm, The height of the convex portion is 0.3 to 2.0 mm. is preferred.

[0012] According to the three-dimensional fabric of the present invention having such a configuration, the three-dimensional pattern is uniformly formed, and the volume, water retention, shape retention when wet, and feel are optimized.

[0013] Furthermore, according to the three-dimensional fabric of the present invention, having perforations; is preferred.

[0014] The three-dimensional fabric of this invention has improved tearability and divisibility, making it suitable for disposable use. Furthermore, by partially cutting the fabric with perforations and creating parallel slits on both sides, it has low pressure loss and less strain when breathing, making it ideal for use as a fire rescue towel (mask) that can be worn over the ears.

[0015] The three-dimensional fabric of the present invention described above has a higher water retention capacity than conventional fabrics, making it suitable for applications requiring ease of wiping, high absorbency, durability, and hygiene, such as disposable hand towels, body towels, emergency preparedness towels, sanitary napkins, baby wipes, and fire rescue towels. [Effects of the Invention]

[0016] The three-dimensional fabric of the present invention has the following significant effects: (1) High-density, thick, three-dimensional shape The grid-like convex portions allow the bag to maintain its expansion even when compressed. (2) Significant increase in water retention capacity Weight 90~120g / m 2 This has resulted in a significant improvement in moisture retention compared to conventional products. (3) Improved wipeability The three-dimensional convex parts efficiently scoop up dirt and provide excellent wiping performance. (4) High shape retention even when wet It does not soggy or lose its fluffy texture, making it pleasant to use. (5) Diversity of uses It can be used not only for hygiene purposes but also for disaster prevention and rescue purposes. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a schematic longitudinal cross-sectional view showing one embodiment of the three-dimensional fabric of the present invention. [Figure 2] 2 is a plan view showing the surface pattern of the grid-shaped convex portions when the three-dimensional fabric 1 shown in FIG. 1 is viewed from the direction of the arrow X. FIG. [Figure 3] FIG. 3 is a partially enlarged view of a grid-shaped convex portion in FIG. 2. DETAILED DESCRIPTION OF THE INVENTION

[0018] A three-dimensional fabric according to a representative embodiment of the present invention will be described in detail below with reference to the drawings. However, the present invention is not limited to the following embodiments. Furthermore, since the drawings are intended to conceptually explain the present invention, dimensions, ratios, or numbers may be exaggerated or simplified as necessary to facilitate understanding.

[0019] [1] About three-dimensional fabrics Here, FIG. 1 is a schematic longitudinal cross-sectional view showing one embodiment of the three-dimensional fabric of the present invention, FIG. 2 is a plan view showing the surface pattern of the lattice-shaped convex portion when the three-dimensional fabric 1 shown in FIG. 1 is viewed from the direction of arrow X, and FIG. 3 is a partially enlarged view of the lattice-shaped convex portion in FIG. 2.

[0020] The three-dimensional fabric 1 of this embodiment is made of a nonwoven fabric 2 containing rayon fibers and polyester fibers (see Fig. 1), and as seen from the direction of arrow X in Fig. 3, convex ridge portions 4 are formed in a lattice pattern on one surface. In this embodiment, the convex ridge portions 4 are aligned in parallel at a constant pitch (interval) both vertically and horizontally to form a lattice pattern.

[0021] From another perspective, linear depressions are provided between the convex ridges. The height of the convex ridges 4 (i.e., the depth of the linear depressions) is a major feature of the present invention. As a result of extensive research, the present inventors have found a combination of specific structures for the nonwoven fabric 2 containing rayon fibers and polyester fibers, which enables the use of a mold with deep grooves in the manufacturing process and allows the formation of aligned convex ridges 4 with sufficient height. This results in a three-dimensional fabric 1 that is excellent in texture, feel, and strength, as well as in three-dimensionality and expansion (especially when folded or rolled), and in water retention, three-dimensionality, and expansion (especially when folded or rolled).

[0022] In this embodiment, the dimensions of the convex portion 4 are vertical width: 2.5 to 5.0 mm, horizontal width: 2.5 to 5.0 mm, and height: 0.3 to 2.0 mm. Such a large lattice pattern achieves recovery after compression, swelling retention after wetting, optimization of the contact area with the skin, and high wiping power.

[0023] The depth of the linear depressions may be 0.3 to 2.0 mm, preferably 0.7 to 1.2 mm, and more preferably 0.5 to 1.0 mm, from the viewpoint of fully achieving the effects of the present invention and allowing a sufficient amount of water to be impregnated into the nonwoven fabric 2. The pitch of the linear depressions 4 in each of the vertical and horizontal directions may be 0.2 to 1.0 cm, preferably 0.3 to 0.7 cm. The depth and pitch may be different in each of the vertical and horizontal directions.

[0024] The nonwoven fabric 2 constituting the three-dimensional fabric 1 of this embodiment is formed by mixing rayon fibers (75 to 85% by mass) and polyester fibers (15 to 25% by mass).

[0025] Rayon fiber provides high water absorption and water retention, while polyester fiber provides strength, wet strength, and abrasion resistance. Therefore, according to the three-dimensional fabric 1 of this embodiment, by setting the ratio of the two fibers within the above range, an optimal balance of thickness, low pressure loss, water retention, strength, flexibility, and shape retention can be obtained.

[0026] There are no particular restrictions on the fineness of the rayon fibers and polyester fibers, and they may be appropriately determined within a range that does not impair the effects of the present invention, for example, 1.0 to 2.0 denier.

[0027] The denier can be measured as follows: For example, a fiber sample is placed in a linear position without tension or load in an atmosphere of 20°C and 65% relative humidity for 24 hours to allow it to relax, and then the sample is cut into 900 mm lengths, and 10 pieces are weighed together and converted into the weight per 9000 m, which can be used as the denier.

[0028] In the case of rayon fibers and polyester fibers with a fineness of less than 1.0 denier, the fibers are too thin, and it is not possible to secure sufficient gaps between the fibers, making it impossible to impregnate the nonwoven fabric 2 with a sufficient amount of moisture, making it difficult to obtain a three-dimensional fabric 1 that has excellent texture, feel, and a refreshing cool feeling and usability.

[0029] Furthermore, in the case of rayon fibers and polyester fibers with a fineness exceeding 2.0 denier, the fibers tend to be too thick and the gaps between the fibers tend to be large, making the nonwoven fabric 2 stiff. Also, the amount of water impregnated into the nonwoven fabric 2 is too large, causing the three-dimensional fabric 1 to swell, resulting in poor texture, feel, coolness, and usability.

[0030] Furthermore, the nonwoven fabric 2 is preferably composed of rayon fibers and polyester fibers with a denier of 1.2 to 1.7. This range allows the nonwoven fabric 2 to be more reliably impregnated with a sufficient amount of moisture, prevents the nonwoven fabric 2 from becoming stiff, and impregnates the nonwoven fabric 2 with an appropriate amount of moisture, resulting in a three-dimensional fabric 1 that is excellent in texture, feel, coolness, and usability.

[0031] The basis weight of the nonwoven fabric 2 of this embodiment is 90 to 120 g / m 2 This range is essential for making a nonwoven fabric thicker and denser than conventional ones, and provides high water content, high shape retention, a fluffy feel after absorbing liquid, and excellent wiping properties.

[0032] The basis weight of a nonwoven fabric can be measured as follows. First, the nonwoven fabric is cut to a predetermined size and used as a measurement piece. This measurement piece is placed on an electronic balance (regardless of manufacturer). The weight in this state is measured and divided by the area to determine the basis weight (g / m 2 ) can be used.

[0033] Here, the three-dimensional fabric 1 of this embodiment may be formed with perforations 6 as shown in Fig. 2. However, Fig. 2 shows a state in which the three-dimensional fabric 1 is cut at the perforations 6.

[0034] These perforations 6 make it easy to separate the required amount from the roll of fabric, making it extremely easy to handle as disposable hand towels, napkins, etc. In other words, the improved tearability and divisibility make it suitable for disposable applications. If the fabric is partially cut along the perforations 6 to create parallel slits on both sides of the roughly rectangular three-dimensional fabric 1, it can also be used as a fire rescue towel (mask) that can be worn over the ears.

[0035] The three-dimensional fabric 1 of this embodiment can be constructed by impregnating the nonwoven fabric 2 in a folded or rolled state with water. The nonwoven fabrics 2 containing water can be individually wrapped in a conventionally known wrapping film such as polyethylene or polyvinyl chloride. If individually wrapped in this way, only the required number of three-dimensional fabrics 1 can be cooled in a refrigerator or heated in a microwave oven, for example.

[0036] As described above, the three-dimensional fabric 1 of this embodiment has significantly better water retention than conventional fabrics. This is presumably because the approximately cubic size of the lattice-shaped convex portions 4 happens to take advantage of the attractive force caused by the intermolecular forces of water, increasing the water retention capacity due to surface tension, making it more difficult for water to move and evaporate.

[0037] The inventors conducted experiments and confirmed that, although a sheet can normally only absorb and retain twice its own weight in water, it was able to absorb and retain 56g of water, four times its own weight (14g), in an environment with a temperature of 20°C and humidity of 35%. Furthermore, when the sheet was hung, the water moved downwards and did not drop to the floor in the form of droplets, even after 120 minutes.

[0038] These experiments have shown that the three-dimensional fabric 1 of this embodiment can be used to create towels that retain sufficient moisture for long-term storage as disaster preparedness supplies by enclosing, for example, an alcohol-free disinfectant for wet tissues in a packaging material with high barrier properties. It can also be used as a head and body cleaning towel, soaked in water and able to thoroughly wipe the face and body when the water supply is cut off.

[0039] Furthermore, even after being soaked in water, the towel can be used as emergency medical gauze or sanitary napkin because it can fully absorb menstrual blood by being tightly wrung out and dried. It can also be used as a fire rescue towel when evacuating in the event of a fire, by covering the mouth or by hanging the above-mentioned slits over both ears, which reduces the absorption of water-soluble gases, smoke, and soot and lowers the temperature of the intake air when breathing.

[0040] [2] Manufacturing method Here, the three-dimensional fabric 1 of this embodiment can be manufactured by a conventionally known method, for example, (1) Rayon and polyester fibers are mixed in a specified ratio (2) Forming a nonwoven web using a carding machine or cross layer (3) Three-dimensional entanglement of fibers by needle punching or hydroentanglement (4) After drying, a grid-like convex pattern is formed using a heat press mold or an embossing roller. (5) Perforation as needed (6) Finished as a sheet or roll It can be manufactured by the following method.

[0041] By stacking a plurality of sheets of the nonwoven fabric obtained as described above and heat-sealing them, a thicker three-dimensional fabric 1 can be realized.

[0042] Next, the nonwoven fabric 2 obtained as described above may be impregnated with water. This water may be tap water, pure water, distilled water, or purified water. It may also contain an antibacterial agent or a cooling agent such as menthol. The nonwoven fabric 2 thus impregnated with water is packaged in a packaging film by a conventional method to obtain the three-dimensional fabric 1 of this embodiment.

[0043] The three-dimensional fabric 1 of this embodiment obtained as described above has a simple structure and can be manufactured through a simple manufacturing process, and has excellent texture, feel, and strength, as well as excellent three-dimensionality and swelling (particularly when folded or rolled), and even when wetted with water (particularly when folded or rolled).

[0044] Furthermore, the inventors have confirmed through experiments that the three-dimensional fabric 1 according to the present invention also has excellent moisturizing and antibacterial effects. [Explanation of symbols]

[0045] 1. Three-dimensional fabric, 2. Nonwoven fabric, 4. Convex part, 6···Perforations.

Claims

1. The fabric contains 75 to 85% by mass of rayon fiber and 15 to 25% by mass of polyester fiber, totaling 100% by mass, and has a basis weight of 90 to 120 g / m ２ It is made of nonwoven fabric, The nonwoven fabric has a surface on which convex portions are formed in a grid pattern. A three-dimensional fabric characterized by:

2. The vertical and horizontal widths of the convex portions are each 2.5 to 5.0 mm, The height of the convex portion is 0.3 to 2.0 mm; The three-dimensional fabric according to claim 1, characterized in that

3. having perforations; The three-dimensional fabric according to claim 1, characterized in that

4. Disposable wet towels, body towels, emergency preparedness towels, sanitary napkins, baby wipes or fire rescue towels. The three-dimensional fabric according to any one of claims 1 to 3, characterized in that

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