Support for non-woven fabric manufacturing

Abstract

To provide a substrate for manufacturing nonwoven fabric, which allows for manufacturing a nonwoven fabric having a horizontal stripe pattern in which at least two types of belt-like parts extending in traverse direction (CD direction) of the nonwoven fabric and having different patterns are repeatedly and regularly disposed in longitudinal direction (MD direction) of the nonwoven fabric.SOLUTION: Fiber web is placed on a substrate for manufacturing nonwoven fabric during manufacturing of a nonwoven fabric. The substrate for manufacturing nonwoven fabric is formed by weaving warp and weft and includes at least two types of a woven texture A and a woven texture B. The woven texture A and the woven texture B are belt-like parts extending along a direction in which the weft extends. The woven texture A and the woven texture B are regularly and repeatedly formed along the direction in which the warp extends on the substrate for manufacturing nonwoven fabric.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a support for manufacturing a non-woven fabric that enables a pattern to be applied to a fiber web when the fiber web is placed and the fibers are integrated during the manufacture of the non-woven fabric.

Background Art

[0002] When manufacturing a non-woven fabric, a method of obtaining a non-woven fabric having a pattern corresponding to the configuration of a support for placing a fiber web (hereinafter sometimes simply referred to as "support") has already been proposed by appropriately selecting the support. For example, when manufacturing a non-woven fabric by jetting a high-pressure fluid flow onto a fiber web to entangle the fibers, the fiber web is placed on a support capable of forming a pattern on the non-woven fabric, and a part of the fiber web is rearranged to form a stripe pattern (Patent Document 1). In addition, as an industrial fabric for imparting concavo-convex marks to a web, an industrial fabric having three predetermined types of pattern area groups has been proposed (Patent Document 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present disclosure provides a support for manufacturing a non-woven fabric that can manufacture a non-woven fabric having a horizontal stripe pattern in which at least two different belt-like portions having different patterns extending in the lateral direction (CD direction) of the non-woven fabric are regularly arranged repeatedly in the longitudinal direction (MD direction) of the non-woven fabric.

Means for Solving the Problems

[0005] This disclosure relates to a support for manufacturing nonwoven fabrics, which is made of warp and weft threads woven together, on which a fiber web is placed during the manufacturing of the nonwoven fabric, It includes at least two types of weave structures A and B, The aforementioned weave structure A and weave structure B are band-shaped portions that extend along the direction in which the weft yarn extends. The weave structure A and the weave structure B are regularly and repeatedly formed along the direction in which the warp threads extend. To provide a support for nonwoven fabric manufacturing. [Effects of the Invention]

[0006] The support of this disclosure enables the manufacture of a nonwoven fabric having a novel design, in which regions with patterns derived from woven structure A and regions with patterns derived from woven structure B are arranged alternately or regularly in the longitudinal direction of the nonwoven fabric. [Brief explanation of the drawing]

[0007] [Figure 1] This is an organizational diagram of an example of the support structure of this embodiment. [Figure 2] This is an organizational diagram of an example of the support structure of this embodiment. [Figure 3] This is a photograph showing the surface of the nonwoven fabric produced in Example 1, which corresponds to an example of a nonwoven fabric produced using the support shown in Figure 1. [Figure 4] This is a photograph showing the surface of the nonwoven fabric produced in Example 2, which corresponds to an example of a nonwoven fabric produced using the support shown in Figure 2. [Figure 5] This is an organizational diagram of an example of the support structure of this embodiment. [Figure 6] This is a photograph showing the surface of the nonwoven fabric produced in Example 3, which corresponds to an example of a nonwoven fabric produced using the support shown in Figure 5. [Figure 7] This is a photograph showing the surface of the nonwoven fabric produced in Example 4. [Figure 8] This is a photograph showing the surface of the nonwoven fabric produced in Example 5. [Figure 9] This is a photograph showing the surface of the nonwoven fabric produced in Example 6. [Figure 10]This is a side cross-sectional photograph showing a method for determining the height difference between the surface of woven fabric A and the surface of woven fabric B in an example of a support of this embodiment. [Figure 11] This is a side cross-sectional photograph showing a method for determining the height difference between the surface of woven fabric A and the surface of woven fabric B in an example of a support of this embodiment. [Figure 12] This is a side cross-sectional photograph showing a method for determining the height difference between the surface of woven fabric A and the surface of woven fabric B in an example of a support of this embodiment. [Modes for carrying out the invention]

[0008] In the nonwoven fabric disclosed in Patent Document 1, the rows or patterned areas constituting the striped pattern extend in the MD direction (longitudinal direction) of the nonwoven fabric, and two or more regions with different patterns are regularly arranged along the CD direction (transverse direction) (hereinafter, such striped patterns will be conveniently referred to as "vertical stripes"). Patent Document 1 provides a method for obtaining vertical stripes by, for example, placing a fiber web on a herringbone net and regularly changing the water jet spraying conditions in the CD direction to form rows having patterns corresponding to the support material. Specifically, a method is disclosed in which rows having patterns corresponding to the support material are formed at intervals by regularly blocking some orifices in a nozzle that sprays water jets and performing a water jet entanglement treatment.

[0009] Patent Document 2 proposes using an industrial fabric having two specific types of pattern regions and a pattern region consisting of a plain weave structure, to form recesses and protrusions in the papermaking product when viewed from the portion formed in relation to the plain weave structure, respectively. In other words, Patent Document 2 proposes an industrial fabric in which recesses and protrusions are formed over a relatively wide area in the papermaking product, making it possible for the recesses or protrusions to appear as characters, for example.

[0010] The inventors focused on the structure of the support on which the fiber web is placed when manufacturing nonwoven fabrics using methods such as high-pressure fluid entanglement or spunbond, in order to obtain stripe patterns that could not be obtained with conventional nonwoven fabrics, and investigated how to configure the support to be suitable for forming stripe patterns. As a result, they devised a support that includes at least two different weave structures, and in which these two different weave structures are arranged alternately along the direction in which the warp threads of the support extend (generally the direction in which the support progresses during nonwoven fabric manufacturing). With such a support, nonwoven fabrics with novel design properties can be manufactured even when using normal high-pressure fluid entanglement or spunbond conditions. The structure of the support for nonwoven fabric manufacturing in this embodiment will be described below.

[0011] The support of this embodiment is a support formed by weaving warp and weft threads, and includes at least two types of weave structures A and B, wherein weave structures A and B are strip-shaped portions that extend along the direction in which the weft threads extend (generally a direction perpendicular to the direction in which the support advances during nonwoven fabric manufacturing, hereinafter also referred to as the "CD direction"), and weave structures A and B are regularly and repeatedly formed along the direction in which the warp threads extend (generally a direction in which the support advances during nonwoven fabric manufacturing, hereinafter also referred to as the "MD direction"). Weave structures A and B extend over the entire width of the support in the CD direction, or over the entire width of the nonwoven fabric to be manufactured in the CD direction. By placing a fiber web on this support and subjecting it to a process that integrates the fibers together, or by depositing molten or softened fibers on this support, regions having patterns (including no patterns) determined by each weave structure are formed.

[0012] In the support, for example, the woven structure A and the woven structure B are arranged in the order of A - B - A - B ··· along the direction in which the warp extends (MD direction). Therefore, if the regions formed in the non-woven fabric by the woven structures A and B of this support are defined as the first region and the second region respectively, in the non-woven fabric, two regions are formed in the order of the first - second region - first region - second region ··· along the MD direction, and a transverse stripe pattern (that is, horizontal stripes) in which the first region and the second region extend along the CD direction orthogonal to the MD direction is formed. Furthermore, it is also possible to add the woven structure C and arrange them in the order of A - B - C - A - B - C ··· along the MD direction. Examples of the woven structure include plain weave, twill weave, satin weave, and suzuhata weave. For example, the woven structure A may be a 2 / 2 twill weave, the woven structure B may be a plain weave, and the woven structure C may be a 3 / 1 twill weave. According to a support incorporating three or more woven structures, in the obtained non-woven fabric, a transverse stripe pattern can be formed in a large number of regions with different surface properties. Also, the exemplified woven structure may be an irregular structure, such as a broken twill. By using an irregular structure, the portions where the warp passes over the weft and floats are dispersed, and the openings or recesses formed due to this floating warp are dispersed, enabling a unique design to be imparted to the non-woven fabric. Also, a support having an irregular woven structure tends to improve the dimensional stability of the support, prevent the support from skewing (drifting) during running, and prevent the occurrence of wrinkles in the production of non-woven fabrics using this support.

[0013] In the support of the present embodiment, the diameters of the weft a constituting the woven structure A and the weft b constituting the woven structure B are different, and the weft a and the weft b may be adjacent to each other at the boundary between the woven structure A and the woven structure B. Also, in the support of the present embodiment, the surface of the woven structure A may be, for example, 0.1 mm or more and 3.0 mm or less higher, particularly 0.5 mm or more and 2.5 mm or less higher, and more particularly 0.8 mm or more and 2.0 mm or less higher than the surface of the woven structure B. With a support having either or both of these configurations, in the non-woven fabric, a narrow third region may be formed at the boundary between the first region and the second region.

[0014] The height difference between the surface of the woven structure A and the surface of the woven structure B is determined as the difference between the highest position of the woven structure A (usually the position where the warp floats at the boundary between the woven structure A and the woven structure B) and the highest position of the woven structure B when observing the side surface or cross-section of the support in the MD direction. When cutting the support to observe the cross-section, depending on the cutting location, the highest position of the woven structure may not be easily visible in the cross-section. In this case, determine the position that is the highest on the back side of the photographed cross-section, or cut the support at different locations to observe different cut surfaces and determine the distance between the highest positions of each tissue. However, when the surface of the tissue is photographed obliquely on the back side of the cross-section, the warp and weft located on the back side shall be ignored when determining the surface height. Depending on the woven structure of the support, the weft may be at the highest position, or the warp may be at the highest position.

[0015] Methods for obtaining the height difference between the surface of the woven structure A and the surface of the woven structure B from the cross-section of the support are shown in FIGS. 10 to 12. FIG. 10 corresponds to the support of the woven structure shown in FIG. 1 described later. In FIG. 10, a line LB passing through the highest position on the surface of the woven structure B and parallel to the surface of the table on which the support is placed, and a line LA passing through the highest position on the surface of the woven structure A (the highest position on the surface of the weft indicated by reference sign a1) and parallel to the surface of the table on which the support is placed are drawn. The distance between LA and LB (the interval in the direction perpendicular to the surface of the table on which the support is placed) corresponds to the height difference between the surface of the woven structure A and the surface of the woven structure B.

[0016] FIG. 11 corresponds to the support of the woven structure shown in FIG. 2 described later, and FIG. 12 corresponds to the support of the woven structure shown in FIG. 5 described later. Similar to FIG. 10, in these figures, LB is a line passing through the highest position on the surface of the woven structure B and parallel to the surface of the table on which the support is placed, and LA is a line passing through the highest position on the surface of the woven structure A (the surface of the warp at the highest position) and parallel to the surface of the table on which the support is placed. In FIG. 11, the surface of the woven structure B appears obliquely on the back side of the cross-section, but this is ignored when obtaining LB.

[0017] In the support structure described above, a step is formed at the boundary between the two structures, and / or a wider gap is formed between the weft threads than in other parts. At this step or gap, the fiber web is subjected to the action of the water flow under different conditions than the fiber web on weave structures A and B, and / or is affected by suction during the water flow entanglement treatment. As a result, a third region with a different pattern from both the first and second regions may be formed as a narrow region.

[0018] Furthermore, at the boundary between weave structure A and weave structure B, due to reasons such as changes in the diameter of the weft threads and changes in the weave structure, the state of the warp threads floating differs from the floating warp threads in weave structure A and weave structure B, forming a section (called a "knuckle") that is thought to create an opening in the third region of the nonwoven fabric obtained by this knuckle. In addition, at the boundary, the weft threads may behave differently from other parts, for example, by meandering, and this is also thought to be a factor in the formation of the third region and / or determine the pattern in the third region.

[0019] The support in this embodiment may have twill weave sections as weave structure A and plain weave sections as weave structure B formed alternately along the MD direction. In such a support, the diameter of weft yarn a may be larger than the diameter of weft yarn b. An example of such a support will be described below with reference to its weave structure.

[0020] The twill weave section, which is weft structure A, may be a weft twill weave structure in which, for example, the number of floating weft threads is 2 or more and the number of floating warp threads is 1. Figure 1 is a structural diagram of a support structure in which weft structure A, which is 1 / 7 of the weft twill weave section, and weft structure B, which is the plain weave section, are formed. Figure 2 is a structural diagram of a support structure in which weft structure A, which is 1 / 3 of the weft twill weave section, and weft structure B, which is the plain weave section, are formed. In the structural diagrams, the colored parts are warp threads floating above the weft threads. Note that Figures 1 and 2, and Figure 5 described later, schematically show the repetition of weft structure A and weft structure B, and the number of warp and weft threads etc. that constitute each structure shown in the drawings are illustrative. Also, examples of nonwoven fabrics manufactured from the supports shown in these drawings are shown in Figures 3, 4 and 6, but the number of warp and weft threads etc. in each region of the support actually used in the manufacture of these nonwoven fabrics may differ from those shown.

[0021] In the support shown in Figure 1, knuckle a is formed at the boundary between the two tissues by the floating portion of the warp threads. In Figure 1, knuckle a is formed when the warp threads float above weft threads a and b. In other areas, the warp threads float above a single weft thread, and knuckle a is formed by the floating of the warp threads in a different state than in other areas. The nonwoven fabric produced using this support has a pattern as shown in Figure 3, and comprises a first region having a diagonal pattern provided by a twill weave (weave structure A), and a second region formed from a plain weave (weave structure B) with openings or recesses arranged in a staggered pattern. Furthermore, a third region is formed, consisting of stitch-like regions with relatively clearly defined openings, which are regularly arranged in the order of first region → third region → second region. This nonwoven fabric corresponds to the nonwoven fabric produced in Example 1, which will be described later, and was produced by a method in which a stream of water as a high-pressure fluid is sprayed onto a fiber web placed on a support as shown in Figure 1 to entangle the fibers.

[0022] In the nonwoven fabric of Figure 3, a third region is formed only at the boundary between one second region and the first region on the lower side of the figure. The third region is formed when water is sprayed onto the fiber web while the support is advanced, with the water flow sequentially sprayed from the fiber web at a lower position (woven structure B) to the fiber web at a higher position (woven structure A). As the support is advanced, the fiber web extending from a lower position to a higher position is thought to be more susceptible to the effects of the water flow, and knuckles and other features at the step are more likely to be reflected in the nonwoven fabric. On the other hand, in the other step where the water flow is sprayed in order from the fiber web at a higher position (woven structure A) to the fiber web at a lower position (woven structure B), some of the water flow "flows down" over the fiber web extending from a higher position to a lower position, and is not firmly received by the fiber web, resulting in a weaker degree of entanglement. As a result, openings and / or recesses are less likely to be formed, and a third region with a clear pattern is not formed, resulting in a nonwoven fabric like the one in Figure 3.

[0023] In the support shown in Figure 2, knuckle a is a warp thread floating above a single weft thread. Knuckle a is the portion where the warp thread passes over the thicker weft thread a, but before and after the direction of knuckle a's progression, the warp thread passes over the thinner weft thread b. Therefore, the arrangement of the weft threads (especially the spacing between weft threads) near knuckle a differs from the arrangement of weft threads in other tissues, and it is thought that this is why knuckle a forms a characteristic opening and / or opening in the third region.

[0024] The nonwoven fabric produced using this support has a pattern as shown in Figure 4, and comprises a first region in which openings provided by the twill weave (weave structure A) are arranged regularly, and a second region in which openings or recesses formed from the plain weave (weave structure B) are arranged in a staggered pattern. In addition, a third region is formed in which stitch-like regions with clearly formed openings are regularly arranged from top to bottom in the figure in the order of first region → third region → second region. This nonwoven fabric corresponds to the nonwoven fabric produced in Example 2, which will be described later, and was produced by a method in which a stream of water as a high-pressure fluid is sprayed onto a fiber web placed on a support as shown in Figure 2 to entangle the fibers. In the first region of the nonwoven fabric shown in Figure 4, relatively clear openings are formed at positions corresponding to the parts where the warp threads are floating in weave structure A. This is thought to be because weave structure A is a 1 / 3 weft-loose twill weave, and the curvature in the floating parts of the warp threads is stronger than that in weave structure A of the support in Figure 1, for example, and the floating parts are more raised. Furthermore, in the woven structure A of the support in Figure 2, continuous diagonal lines are not formed due to the floating warp threads, so diagonal patterns are less likely to form in the first region of the resulting nonwoven fabric.

[0025] The nonwoven fabric shown in Figure 4 also has a structure in which the first region → third region → second region are repeatedly formed, and the third region is formed only at the boundary with the first region on the lower side of the figure when viewed from one second region. The reason for the formation of the third region in this way is thought to be the same as the reason explained with reference to Figure 3 above.

[0026] In the support of this embodiment, the weave structure A is not limited to having 1 warp thread floating, but may be a twill weave section with 2 or more warp thread floating. The upper limit of the warp thread floating may be, for example, 16, and particularly 10. In this case, the number of weft thread floating may be, for example, 2 or more and 16 or less, and particularly 2 or more and 10 or less. For example, the support of this embodiment may have a weave structure A which is a 2 / 2 twill weave section and a weave structure B which is a plain weave section, as shown in the structure diagram of Figure 5.

[0027] In twill weave sections where the number of floating warp threads is two or more, a characteristic knuckle is formed at the boundary with the plain weave section. As shown in Figure 5, at one boundary of the twill weave section to the plain weave section, a knuckle N1 is formed floating on three or more consecutive weft threads, including weft threads a and b. Because this knuckle N1 is elongated in the vertical direction, it tends to form a vertically elongated opening at the boundary between the first and second regions.

[0028] Furthermore, in the support shown in Figure 5, a knuckle N2 is formed at the boundary opposite to the boundary on the side where knuckle N1 is formed, where the warp threads float over two or more consecutive weft threads including weft threads a and b. Adjacent to one side of knuckle N2, a knuckle N3 is formed where the warp threads float over two or more consecutive weft threads. Since knuckles N2 and N3 are formed in close proximity, in the resulting nonwoven fabric, a region is formed between the first region and the second region where two adjacent openings or two openings are connected to form one larger opening.

[0029] As shown in the support in Figure 5, if the number of warp floats (the number of weft threads that are continuously positioned above a warp thread) and the number of weft floats (the number of warp threads that are continuously positioned above a weft thread) are the same in the woven structure, then the number of warp and weft floats will be the same on both main surfaces. Such a support makes it possible to manufacture nonwoven fabrics with substantially the same pattern, regardless of which of the two main surfaces is used as the surface on which the fiber web is placed. However, in the twill weave section, the direction of the diagonal lines formed by the warp threads is mirror-image symmetrical between the two main surfaces, and the direction of the diagonal lines formed in the resulting nonwoven fabric will be opposite.

[0030] Figure 6 shows an example of a nonwoven fabric manufactured using the support shown in Figure 5. The nonwoven fabric in Figure 6 corresponds to the nonwoven fabric manufactured in Example 3, and was manufactured by entangling the fibers by spraying a water flow as a high-pressure fluid stream onto a fiber web placed on a support as shown in Figure 5. This nonwoven fabric was manufactured by performing the water flow entanglement treatment so that the boundary where the knuckle N1 is formed is sprayed into the water flow first, that is, with the arrow shown on the right side of the structural diagram in Figure 5 as the direction of travel. In the nonwoven fabric in Figure 6, the first region has a diagonal pattern in which diagonal lines with openings and diagonal lines without openings are arranged alternately. The openings correspond to the parts where the warp threads are floating in the twill weave section of Figure 5, and because the warp threads floating on two weft threads are adjacent in the twill weave section, relatively clear openings are formed in the nonwoven fabric.

[0031] The nonwoven fabric in Figure 6 has a third region formed corresponding to the boundary containing knuckle N1, and a fourth region formed corresponding to the boundary containing knuckles N2 and N3. The four regions are formed repeatedly in the order of first region → third region → second region → fourth region. Both the third and fourth regions have different patterns from the first and second regions, emphasizing the boundary between the first and second regions. Because knuckle N1 is long and floating above three weft threads, it makes the opening in the third region larger than the opening formed in the first region, and the direction of the diagonal lines formed in the opening of the first region appears to be changed in the third region. Knuckle N2 passes over the weft threads constituting weft structure A and weft structure B at the boundary between weft structures A and B, so the warp threads reach a lower position on the weft structure B side before passing under the weft threads of weft structure B. This is thought to be what makes the pattern of the fourth region different from the other regions. Furthermore, at the boundary between weave structure A and weave structure B, the spacing of the weft threads tends to be wider than that in weave structure A and weave structure B, which is also thought to be what makes the patterns in the third and fourth regions different from those in the other regions.

[0032] In the nonwoven fabric of Figure 6, regions with patterns different from those of the first and second regions are formed at the upper and lower boundaries of the figure, as viewed from the second region. Knuckles N2 and N3 are relatively large because the warp threads are floating above two weft threads. Therefore, even when water flow acts sequentially on the fiber web spanning from a high position to a low position, the knuckles are more susceptible to influence, and it is thought that a clearer pattern is formed compared to the supports in Figures 1 and 2 (where the number of floating warp threads is 1 in the knuckles at the boundary of the woven structure on the rear side in the direction of travel).

[0033] The illustrated support is an example, and the weave structures A and B may be other than those shown. Furthermore, the width in the MD direction of each weave structure, the diameters of the wefts a and b, and the diameter of the warp threads are appropriately selected to obtain the desired pattern in the nonwoven fabric.

[0034] In the support, the MD-direction dimensions of woven structures A and B determine the MD-direction dimensions of the first and second regions formed in the resulting nonwoven fabric (i.e., the dimensions in the X-direction, where the direction in which the first and second regions are repeatedly formed is the X-direction). In this embodiment, the MD-direction dimensions of woven structure A may be 2 mm or more and 200 mm or less, particularly 3 mm or more and 100 mm or less, more particularly 5 mm or more and 50 mm or less, even more particularly 7 mm or more and 30 mm or less, and even more particularly 10 mm or more and 25 mm or less. Similarly, the MD-direction dimensions of woven structure B may be 2 mm or more and 200 mm or less, particularly 3 mm or more and 100 mm or less, more particularly 5 mm or more and 50 mm or less, even more particularly 7 mm or more and 30 mm or less, and even more particularly 10 mm or more and 25 mm or less. The MD-direction dimensions of woven structure A may be the same as or different from the MD-direction dimensions of woven structure B. Furthermore, a single support may contain multiple woven structures A with different dimensions in the MD direction, and / or multiple woven structures B with different dimensions in the MD direction.

[0035] The warp and weft threads constituting the support may be, for example, filaments with a diameter of 0.3 mm to 1.2 mm. The diameter of the weft may be, for example, 0.5 mm to 1.2 mm, particularly 0.9 mm to 1.0 mm, and more particularly 0.65 mm to 0.95 mm. Weft threads a and b may have different diameters. In that case, the difference in diameter between weft threads a and b may be, for example, 0.1 mm to 0.8 mm, particularly 0.2 mm to 0.7 mm, and more particularly 0.3 mm to 0.6 mm. The larger the difference in diameter between weft threads a and b, the clearer the pattern in the third and fourth regions of the formed nonwoven fabric tends to be. However, if the difference is too large, the woven structure B and the fiber web may not come into contact (the gap may be large) near the boundary between woven structure A and woven structure B, and conversely, a clear pattern may not be formed. Furthermore, the warp threads that make up the support are common to both weave structures A and B, and their thickness is the same in both weave structures A and B.

[0036] The diameters of the warp and weft threads are determined by the length of the longest line segment connecting any two points in the cross-section (the cross-section obtained by cutting perpendicular to the length direction) of the thread (e.g., filament). This method can also be used to determine the diameter of threads with cross-sectional shapes such as elliptical, polygonal, bean-shaped, comma-shaped, or star-shaped. However, as described later, for filaments with a flattened cross-section (including rectangles with rounded corners), the dimensions of the short and long sides of the rectangle circumscribing the cross-section are used as an indicator of its thickness.

[0037] The warp and weft threads constituting the support may be monofilaments having a flattened cross-section, with a rectangle circumscribing the cross-section having a short side of 0.2 mm to 0.8 mm and a long side of 0.3 mm to 1.2 mm. The short side of the circumscribing rectangle may be particularly 0.4 mm to 0.6 mm, and the long side may be particularly 0.7 mm to 0.9 mm. Here, "flattened shape" refers to shapes with large dimensions in one direction, such as rectangles, ellipses, and rectangles with rounded corners, where it is difficult to conceptualize the dimensions and shape solely by the diameter obtained by the above method. If the cross-section is a perfect rectangle, the short and long sides of the rectangle will have dimensions within the above range. The ratio of the length of the long side to the length of the short side of the circumscribing rectangle (length / short side ratio) may be, for example, 1.2 or more, particularly 1.3 to 3, and more particularly 1.4 to 2.

[0038] In this embodiment, it is preferable that the warp threads constituting the support are flattened. This is because using flattened warp threads makes it easier to improve the flexibility and dimensional stability of the support in the MD direction compared to using warp threads with a circular cross-section. Furthermore, using flattened warp threads increases the contact area between the warp threads and the fiber web, and tends to increase the area of ​​the openings formed by the floating portions of the warp threads, including knuckles. In addition, when the warp threads have a rectangular cross-section with rounded corners, the bending resistance of the support tends to improve.

[0039] The warp and weft threads constituting the support may be formed from one or more materials selected from polyester, polyamide, polyolefin, polyetheretherketone, and polyphenylene sulfide. Furthermore, the warp and weft threads may be in forms other than monofilament, such as multifilament or spun yarn. In the case of multifilament, fineness may be used instead of diameter as an indicator of yarn thickness, and weft threads a and b with different fineness may be used.

[0040] The weaving density of the support in this embodiment may be, for example, 6 threads / inch or more and 123 threads / inch or less for the warp threads, particularly 10 threads / inch or more and 80 threads / inch or less, and more particularly 20 threads / inch or more and 40 threads / inch or less. The weaving density of the weft threads may be, for example, 6 threads / inch or more and 123 threads / inch or less, particularly 8 threads / inch or more and 60 threads / inch or less, and more particularly 10 threads / inch or more and 20 threads / inch or less. The higher the weaving density, the easier it is to impart a clearer pattern to the nonwoven fabric due to the floating parts of the warp threads containing knuckles. However, if the weaving density is too high, the smoothness of the floating parts of the warp threads containing knuckles increases, which may actually reduce the clarity of the pattern.

[0041] When the weave structure A is a twill weave, the shape of the diagonal pattern in the first region of the resulting nonwoven fabric changes not only with the diameter of the monofilaments, the warp density, and the weft density, but also with the number of warp threads floating above and / or below the weft in the twill weave. The twill weave structure consists of warp threads floating above adjacent or non-adjacent locations, and when the floating warp threads are connected by a straight line, if a straight line extending diagonally while including all the floating locations can be drawn, a first region with a diagonal pattern as shown in Figures 3 and 6 is obtained. If such a straight line cannot be drawn, a first region with a pattern of less regularity in the arrangement of openings or recesses, as shown in Figure 4, is obtained.

[0042] When the weave structure B is a plain weave, the dimensions of the openings formed in the second region change depending on the diameter of the monofilaments that make up the structure, and the larger the diameter of the monofilaments, the larger the area of ​​the openings tends to be. In addition, the spacing between openings, between openings and recesses, or between recesses changes depending on the weft density and warp density of the plain weave, and the spacing tends to become narrower as the weft density and / or warp density increase.

[0043] In the support structure, both weave structures A and B may be plain weaves. In this case, the two weave structures can be made different from each other by changing the diameter of the weft threads and / or the density of the weft threads. Alternatively, both weave structures A and B may be twill weaves. In this case, the two weave structures can be made different from each other by using one method selected from changing the number of warp threads floating above the weft threads, changing the number of warp threads submerged beneath the weft threads, changing the diameter of the weft threads, etc.

[0044] If the weave structure B is a fine plain weave (for example, 80 mesh to 100 mesh), a patternless second region is formed corresponding to that structure. In this case, the weave structure A may be a structure capable of forming a pattern, such as a twill weave, or a plain weave consisting of large diameter filaments.

[0045] The support of this embodiment is manufactured by weaving using warp and weft threads in a conventional manner so that weave structures A and B are regularly and repeatedly formed. After weaving, preferably, the support is subjected to a heat-setting process in which tension is applied in the MD direction (the direction in which the warp threads extend) or the CD direction (the direction in which the weft threads extend) while heat treatment is performed. Heat setting provides dimensional stability. The tension is preferably, for example, 1 kg / cm or more and 20 kg / cm or less. The temperature is preferably, for example, 80°C or more and 250°C or less.

[0046] The support of this embodiment is suitable for use in a method in which a high-pressure fluid flow (especially a water flow) is sprayed onto a fiber web to rearrange and entangle the fibers, thereby integrating them. An example of a nonwoven fabric produced by this method is described above.

[0047] The support of this embodiment is also suitable for use in the manufacture of nonwoven fabrics by the spunbond method. The spunbond method is a method of manufacturing nonwoven fabrics by opening and depositing melt-spun fibers on a support to create a fiber web, and then subjecting the fiber web to a process that bonds the fibers together (e.g., embossing). The support of this embodiment is preferably used as a support when depositing melt-spun fibers to create a fiber web. This is because when melt-spun fibers are deposited on the support, the fibers are in a molten or softened state, so the pattern of the support is easily reflected in the fiber web, and this is maintained in the nonwoven fabric. In the spunbond method, unlike the high-pressure fluid entanglement method, the fibers are not rearranged by external forces during nonwoven fabric production. Therefore, openings are less likely to form in nonwoven fabrics produced by the spunbond method, but the unevenness of the support material, such as areas where the warp threads are floating (including knuckles), tends to be more clearly reflected and appear as distinct irregularities.

[0048] Alternatively, the support of this embodiment may be used to place a fiber web and to bond the fibers constituting the fiber web together either by themselves or by an adhesive.

[0049] The support may be an endless structure formed by joining its ends in the direction parallel to the lateral direction (the direction perpendicular to the direction of movement of the support), or it may be rectangular in shape. When using a rectangular support, the rectangular support of this embodiment may be laid out on top of another endless support and fixed to the other support, thereby enabling continuous nonwoven fabric manufacturing. [Examples]

[0050] The support of this embodiment and the nonwoven fabric manufactured using said support will be described by reference to examples.

[0051] (Example 1) As support material 1, a fabric was prepared in which weave structure A was a 1 / 7 twill weave section and weave structure B was a plain weave section, with weave structures A and B arranged alternately in the MD direction. In support material 1, polyester monofilament with a rounded rectangular cross-section and dimensions of the circumscribing rectangle of the cross-section being 0.88 mm long side × 0.57 mm short side was used as the warp thread, and polyester monofilament with a diameter of 0.9 mm was used as the weft thread a and polyester monofilament with a diameter of 0.45 mm was used as the weft thread b. In the manufacturing of support material 1, after weaving was completed, heat setting was performed at 150°C while applying a tension of 2 kg / cm in the MD direction. In support material 1, the warp density was 30 threads / inch and the weft density was 25 threads / inch, the MD direction dimension of weave structure A was 15 mm and the MD direction dimension of weave structure B was 8 mm. In support material 1, the surface of weave structure A was 1.5 mm higher than the surface of weave structure B.

[0052] The difference in height between the surface of woven structure A and the surface of woven structure B was determined by photographing the MD-direction cross-section of the support using an image analysis processing device (Hyrox KH-3000) and using the method described above.

[0053] Using support 1, a nonwoven fabric was manufactured according to the following procedure. A fiber web was produced by mixing 80% rayon by mass and 20% PP / PE by mass using a parallel carding machine. The basis weight of this fiber web was approximately 40 g / m². 2 That was the case. [First water flow entanglement treatment (overall entanglement treatment)] The aforementioned fiber web was placed on a plain weave net with warp thread diameters of 0.132 mm, weft thread diameters of 0.132 mm, and a mesh count of 90. While the fiber web was advanced at a speed of 4 m / min, a columnar water stream at a water pressure of 1.0 MPa was sprayed onto the surface of the fiber web, followed by a columnar water stream at a water pressure of 1.5 MPa on the back surface of the fiber web. A nozzle with orifices of 0.12 mm in diameter spaced 0.6 mm apart was used to spray the water streams. The distance between the surface of the fiber web and the orifices was 15 mm.

[0054] [Second water flow entanglement treatment (striped pattern formation treatment)] The fiber web, after undergoing the first water flow entanglement treatment, was placed on the support 1, and while the fiber web was advanced at a speed of 4 m / min, a columnar water stream with a water pressure of 1.5 MPa was sprayed onto the back surface of the fiber web. The same nozzle used in the first water flow entanglement treatment was used for spraying the water stream. The second water flow entanglement treatment yielded a nonwoven fabric having the first to third regions shown in Figure 3. More specifically, each region extended along the CD direction (i.e., the CD direction is the Y direction), and the first region consisted of a diagonal pattern area, and the second region consisted of a pattern area with openings arranged in a staggered pattern, which alternately repeated in the MD direction, forming a striped pattern. The third region was a region with slightly larger openings arranged linearly between the first and second regions.

[0055] [Heat treatment] The nonwoven fabric after the second water flow entanglement treatment was heated at 135°C for approximately 5 seconds using a hot air penetration type heat treatment machine to perform a drying treatment, and at the same time, the fibers were heat-bonded together by the PP / PE sheath component to obtain the nonwoven fabric of Example 1.

[0056] (Example 2) As support material 2, a fabric was prepared in which weave structure A was a 1 / 3 loose twill weave section (loose twill, 4 warp threads per section) and weave structure B was a plain weave section, with weave structures A and B arranged alternately in the MD direction. In support material 2, polyester monofilament with a rounded rectangular cross-section and dimensions of the circumscribing rectangle of the cross-section being 0.88 mm long side × 0.57 mm short side was used as the warp thread, and polyester monofilament with a diameter of 0.8 mm was used as weft thread a and polyester monofilament with a diameter of 0.45 mm was used as weft thread b. In the manufacturing of support material 2, after weaving was completed, heat setting was performed at 150°C while applying a tension of 2 kg / cm in the MD direction. In support material 2, the warp density was 30 threads / inch and the weft density was 17 threads / inch, the MD direction dimension of weave structure A was 15 mm and the MD direction dimension of weave structure B was 8 mm. In support 2, the surface of woven structure A was located 1.0 mm higher than the surface of woven structure B.

[0057] The nonwoven fabric of Example 2 was obtained using the same procedure as that used in the production of Example 1, except that support 2 was used in the second water flow entanglement treatment. The second water flow entanglement treatment yielded a nonwoven fabric having the first to third regions shown in Figure 3. More specifically, each region extended along the CD direction (i.e., the CD direction is the Y direction), and the first region consisted of a patterned area with irregularly formed openings, while the second region consisted of a patterned area with openings arranged in a staggered pattern, which alternately repeated in the MD direction, forming a striped pattern. The third region was a region with slightly larger openings arranged linearly between the first and second regions.

[0058] (Example 3) As support material 3, a fabric was prepared in which weave structure A was a 2 / 2 twill weave section and weave structure B was a plain weave section, with weave structures A and B arranged alternately in the MD direction. In support material 3, polyester monofilament with a rounded rectangular cross-section and dimensions of the circumscribing rectangle of the cross-section being 0.88 mm long side × 0.57 mm short side was used as the warp thread, and polyester monofilament with a diameter of 0.9 mm was used as weft thread a and polyester monofilament with a diameter of 0.45 mm was used as weft thread b. In the manufacturing of support material 3, after weaving was completed, heat setting was performed at 150°C while applying tension of 2 kg / cm in the MD direction. In support material 3, the warp density was 30 threads / inch and the weft density was 17 threads / inch, the MD direction dimension of weave structure A was 20 mm and the MD direction dimension of weave structure B was 10 mm. In support material 3, the surface of weave structure A was 0.8 mm higher than the surface of weave structure B.

[0059] The nonwoven fabric of Example 3 was obtained using the same procedure as that used in the production of Example 1, except that support 3 was used in the second water flow entanglement treatment. The second water flow entanglement treatment yielded a nonwoven fabric having the first to fourth regions shown in Figure 6. More specifically, each region extended along the CD direction (i.e., the CD direction is the Y direction), and the first region consisted of a diagonal pattern, while the second region consisted of a pattern with openings arranged in a staggered pattern, which alternately repeated in the MD direction, forming a striped pattern. The third and fourth regions were formed at the boundary between the first and second regions.

[0060] (Example 4) As support material 4, a fabric was prepared in which weave structure A was a 1 / 7 twill weave section and weave structure B was a plain weave section, with weave structures A and B arranged alternately in the MD direction. In support material 4, polyester monofilament with a rounded rectangular cross-section and dimensions of the circumscribing rectangle of the cross-section being 0.88 mm long side × 0.57 mm short side was used as the warp threads, and polyester monofilament with a diameter of 0.9 mm was used as weft thread a and polyester monofilament with a diameter of 0.45 mm was used as weft thread b. In the manufacturing of support material 4, after weaving was completed, heat setting was performed at 150°C while applying tension of 2 kg / cm in the MD direction. In support material 4, the warp density was 30 threads / inch and the weft density was 25 threads / inch, the MD direction dimension of weave structure A was 15 mm and the MD direction dimension of weave structure B was 20 mm. In support material 4, the surface of weave structure A was 1.6 mm higher than the surface of weave structure B.

[0061] The nonwoven fabric of Example 4 was obtained using the same procedure as that used in the production of Example 1, except that support material 4 was used in the second water flow entanglement treatment. The second water flow entanglement treatment yielded a nonwoven fabric having the first to third regions shown in Figure 10. More specifically, each region extended along the CD direction (i.e., the CD direction is the Y direction), and the first region consisted of a diagonal pattern area, while the second region consisted of a pattern area with openings arranged in a staggered pattern, which alternately repeated in the MD direction, forming a striped pattern. The third region was a region with slightly larger openings arranged linearly between the first and second regions.

[0062] (Example 5) As support material 5, a fabric was prepared in which weave structure A was a 2 / 2 twill weave section and weave structure B was a plain weave section, with weave structures A and B arranged alternately in the MD direction. In support material 5, polyester monofilament with a rounded rectangular cross-section and dimensions of the circumscribing rectangle of the cross-section being 0.88 mm long side × 0.57 mm short side was used as the warp threads, and polyester monofilament with a diameter of 0.9 mm was used as weft thread a and polyester monofilament with a diameter of 0.45 mm was used as weft thread b. In the manufacturing of support material 5, after weaving was completed, heat setting was performed at 150°C while applying tension of 2 kg / cm in the MD direction. In support material 5, the warp density was 30 threads / inch and the weft density was 17 threads / inch, and the dimensions of weave structure A in the MD direction were 6 mm and 6 mm respectively. In support material 5, the surface of weave structure A was 0.6 mm higher than the surface of weave structure B.

[0063] The nonwoven fabric of Example 5 was obtained using the same procedure as that used in the production of Example 1, except that support 5 was used in the second water flow entanglement treatment. The second water flow entanglement treatment yielded a nonwoven fabric having the first to fourth regions shown in Figure 11. More specifically, each region extended along the CD direction (i.e., the CD direction is the Y direction), and the first region consisted of a diagonal pattern, while the second region consisted of a pattern with openings arranged in a staggered pattern, which alternately repeated in the MD direction, forming a striped pattern. At the boundary between the first and second regions, the third and fourth regions were formed, consisting of somewhat larger openings arranged linearly.

[0064] (Example 6) As support material 6, a fabric was prepared in which weave structure A was a 2 / 2 twill weave section and weave structure B was a plain weave section, with weave structures A and B arranged alternately in the MD direction. In support material 6, polyester monofilaments with a rounded rectangular cross-section and a circumscribing rectangle with dimensions of 0.88 mm long side × 0.57 mm short side were arranged alternately as warp threads, with weft thread a being a polyester monofilament with a diameter of 0.9 mm and weft thread b being a polyester monofilament with a diameter of 0.45 mm. In the manufacture of support material 6, after weaving was completed, heat setting was performed at 150°C while applying a tension of 2 kg / cm in the MD direction. In support material 6, the warp density was 30 threads / inch and the weft density was 17 threads / inch, and the MD direction dimension of weave structure A was 10 mm and the MD direction dimension of weave structure B was 10 mm. In support material 6, the surface of weave structure A was 0.45 mm higher than the surface of weave structure B.

[0065] The nonwoven fabric of Example 6 was obtained using the same procedure as that used in the production of Example 1, except that support 6 was used in the second water flow entanglement treatment. The second water flow entanglement treatment yielded a nonwoven fabric having the first to third regions shown in Figure 12. More specifically, each region extended along the CD direction (i.e., the CD direction is the Y direction), and the first region consisted of a diagonal pattern, while the second region consisted of a pattern with openings arranged in a staggered pattern, which alternately repeated in the MD direction, forming a striped pattern. At the boundary between the first and second regions, third and fourth regions were formed, consisting of somewhat larger openings arranged linearly.

[0066] This embodiment includes the following aspects: (Aspect 1) A support for manufacturing nonwoven fabrics, which is made of warp and weft threads and on which a fiber web is placed during the manufacturing of nonwoven fabrics, It includes at least two types of weave structures A and B, The aforementioned weave structure A and weave structure B are band-shaped portions that extend along the direction in which the weft yarn extends. The weave structure A and the weave structure B are regularly and repeatedly formed along the direction in which the warp threads extend. Support for nonwoven fabric production. (Aspect 2) A support for manufacturing nonwoven fabric according to Embodiment 1, wherein the diameters of the weft yarn a constituting the weave structure A and the weft yarn b constituting the weave structure B are different, and the weft yarn a and the weft yarn b are adjacent to each other at the boundary between the weave structure A and the weave structure B. (Aspect 3) A support for manufacturing nonwoven fabrics according to embodiment 1 or 2, wherein the surface of the woven structure A is located 0.1 mm to 3.0 mm higher than the surface of the woven structure B. (Aspect 4) A support for manufacturing nonwoven fabrics, in any of embodiments 1 to 3, wherein the warp thread, the weft thread a, and the weft thread b are each monofilaments with a diameter of 0.3 mm or more and 1.2 mm or less, or monofilaments having a flattened cross-section, with a rectangle circumscribing the cross-section having a short side of 0.2 mm or more and a long side of 0.3 mm or more and 1.2 mm or less, and a long side / short side ratio of 1.2 or more. (Appendix 5) A support for manufacturing nonwoven fabrics, wherein the woven structure A is a weft twill weave with 2 or more floating weft threads and 1 floating warp thread, and the woven structure B is a plain weave, according to any of embodiments 1 to 4. (Aspect 6) A support for manufacturing nonwoven fabric, wherein the weft yarn a is thicker than the weft yarn b, according to any of embodiments 1 to 5. (Aspect 7) A support for manufacturing a nonwoven fabric, wherein at the boundary between the woven structure A and the woven structure B, a knuckle N1 is formed on two or more consecutive wefts, including the weft a and the weft b, on which the warp threads are suspended, in any of embodiments 1 to 6. (Pattern 8) A support for manufacturing nonwoven fabrics, in any embodiment from 1 to 7, wherein, as viewed from the woven structure A, a knuckle N2 is formed at the boundary with the woven structure B on the side opposite to the side where the knuckle N1 is formed, in which the warp threads float over two or more consecutive weft threads including the weft threads a and b, and adjacent to either side of the knuckle N2, a knuckle N3 is formed in which the warp threads float over two or more consecutive weft threads. (Aspect 9) A support for manufacturing nonwoven fabrics, wherein the woven structure A is a twill weave with 2 to 16 floating weft threads and 2 to 16 floating warp threads, the woven structure B is a plain weave, and the diameter of the weft thread a is greater than the diameter of the weft thread b, in any of embodiments 1 to 8. (Aspect 10) A support for manufacturing nonwoven fabrics, used when entangling fibers with a high-pressure fluid flow, according to any of embodiments 1 to 9. (Aspect 11) A support for manufacturing nonwoven fabrics, used in the manufacturing of nonwoven fabrics by the spunbond method, according to any of embodiments 1 to 9. (Aspect 12) To create a fiber web, The fiber web is placed on a nonwoven fabric manufacturing support in any of the embodiments 1 to 10, and subjected to a process that binds and / or entangles the fibers constituting the fiber web. A method for manufacturing nonwoven fabrics, including the method described above. (Aspect 13) A method for producing a nonwoven fabric, comprising depositing filaments obtained by melt-spinning a synthetic resin onto a support for nonwoven fabric production, one of the embodiments 1 to 9, while the synthetic resin is melting or softening. [Industrial applicability]

[0067] The nonwoven fabric manufacturing support disclosed herein enables the production of a novel striped nonwoven fabric in which strip-shaped portions of different patterns extending in the CD direction of the nonwoven fabric are regularly arranged in the MD direction, and is useful as a support used in nonwoven fabric manufacturing by the high-pressure fluid flow entanglement method and the spunbond method.

Claims

1. A support for manufacturing nonwoven fabrics, which is made of warp and weft threads and on which a fiber web is placed during the manufacturing of nonwoven fabrics, It includes at least two types of weave structures A and B, The aforementioned weave structure A and weave structure B are strip-shaped portions that extend along the direction in which the weft yarn extends, The weave structure A and the weave structure B are regularly and repeatedly formed along the direction in which the warp threads extend. Support for nonwoven fabric production.

2. The support for manufacturing a nonwoven fabric according to claim 1, wherein the diameters of the weft yarn a constituting the weave structure A and the weft yarn b constituting the weave structure B are different, and the weft yarn a and the weft yarn b are adjacent to each other at the boundary between the weave structure A and the weave structure B.

3. The support for manufacturing nonwoven fabric according to claim 1 or 2, wherein the surface of the woven structure A is located at a position 0.1 mm to 3.0 mm higher than the surface of the woven structure B.

4. A support for manufacturing nonwoven fabric according to claim 2, or claim 3, which references claim 2, wherein the warp thread, the weft thread a, and the weft thread b are each monofilaments with a diameter of 0.3 mm or more and 1.2 mm or less, or monofilaments having a flattened cross-section, with a rectangle circumscribing the cross-section having a short side of 0.2 mm or more and a long side of 0.3 mm or more and 1.2 mm or less, and a long side / short side ratio of 1.2 or more.

5. The support for manufacturing nonwoven fabric according to any one of claims 1 to 4, wherein the weave structure A is a twill weave structure in which the number of floating weft threads is 2 or more and the number of floating warp threads is 1, and the weave structure B is a plain weave structure.

6. A support for manufacturing nonwoven fabric according to any one of the following: the weft yarn a is thicker than the weft yarn b, the support according to claim 2, or claim 3 or claim 4 relating to claim 2, or claim 5 relating to claim 2 or 4.

7. A support for manufacturing nonwoven fabric according to claim 2, or claim 3 or claim 4, or claim 5 or claim 6, which references claim 2 or 4, wherein a knuckle N1 is formed at the boundary between the woven structure A and the woven structure B, on two or more consecutive wefts including the weft a and the weft b, with the warp thread floating above it.

8. A support for manufacturing nonwoven fabric according to claim 7, wherein, as viewed from the woven fabric A, a knuckle N2 is formed at the boundary with the woven fabric B on the side opposite to the side where the knuckle N1 is formed, in which the warp threads float on two or more consecutive weft threads including the weft threads a and b, and adjacent to either side of the knuckle N2, a knuckle N3 is formed in which the warp threads float on two or more consecutive weft threads.

9. A support for manufacturing nonwoven fabric according to claim 2, or claim 3, or claim 4, or any of claims 6 to 8, relating to claim 2, or claim 2, or claim 4, relating to claim 2.

10. A support for manufacturing nonwoven fabrics according to any one of claims 1 to 9, used when entangling fibers with a high-pressure fluid flow.

11. A support for manufacturing nonwoven fabrics according to any one of claims 1 to 9, used when manufacturing nonwoven fabrics by the spunbond method.

12. To create a fiber web, The fiber web is placed on a nonwoven fabric manufacturing support according to any one of claims 1 to 10, and subjected to a process that binds and / or entangles the fibers constituting the fiber web. A method for manufacturing nonwoven fabrics, including the method described above.

13. A method for producing a nonwoven fabric, comprising depositing a filament obtained by melt-spinning a synthetic resin onto a support for producing a nonwoven fabric according to any one of claims 1 to 9 or claim 11 while the synthetic resin is melting or softening.

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