Stretchable bulky nonwoven fabric and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-9422652-B2
Application number	US-201213649115-A
Country	US
Kind code	B2
Filing date	Oct 11, 2012
Priority date	Oct 12, 2011
Publication date	Aug 23, 2016
Grant date	Aug 23, 2016

Abstract

To provide a stretchable bulky nonwoven fabric having a high bulkiness and a good feeling; wherein a first fibrous layer including fibers ( 1 ) is laminated with a second fibrous layer including heat fusible fibers ( 2 ) and having a MD shrinkage ratio lower by 5% or more than a MD shrinkage ratio of the first fibrous layer, the first fibrous layer and the second fibrous layer are integrated by entanglement between the fibers ( 1 ) included in the first fibrous layer and fibers ( 2 ) included in the second fibrous layer, the first fibrous layer is shrunk to form a structure in which the second layer is raised in the thickness direction, and sonic bond processing is applied from a side of the second fibrous layer.

First claim

What is claimed is:

1. A stretchable bulky nonwoven fabric, wherein a first fibrous layer including fibers ( 1 ) is laminated with a second fibrous layer including heat fusible fibers ( 2 ) and having a MD shrinkage ratio that is lower by 5% or more than a MD shrinkage ratio of the first fibrous layer, the first fibrous layer and the second fibrous layer are integrated by partial entanglement of the fibers ( 1 ) included in the first fibrous layer and the fibers ( 2 ) included in the second fibrous layer at an interface between the first fibrous layer and the second fibrous layer in a thickness direction of the nonwoven fabric, wherein partial entanglement comprises entanglements and regions between the entanglements, the first fibrous layer is shrunk to form a structure in which the second fibrous layer is raised in a thickness direction at the regions between the entanglements, and sonic bond processing is partially applied to the first and second fibrous layers from a side of the second fibrous layer after the entanglement and shrinkage, wherein the entanglement and shrinkage are simultaneously achieved by increasing a temperature to a level in which helical crimps are developed in fibers ( 1 ) or to a higher level, and the fibers ( 1 ) develop helical crimps and shrink so as to tangle the fibers ( 2 ) included in the second fibrous layer.

2. The stretchable bulky nonwoven fabric according to claim 1 , including concave parts foa med by the sonic bond processing, and convex parts formed by sites being not subjected to the sonic bond processing.

3. The stretchable bulky nonwoven fabric according to claim 2 , wherein thickness of the convex parts is in the range of 1.0 to 5.0 mm.

4. The stretchable bulky nonwoven fabric according to claim 2 , having apertures obtained by removing sites forming thickness of the concave parts.

5. The stretchable bulky nonwoven fabric according to claim 1 , wherein the MD shrinkage ratio of the fibers ( 1 ) is 40% or more.

6. The stretchable bulky nonwoven fabric according to claim 1 , wherein a method for manufacturing the stretchable bulky nonwoven fabric, comprises: laminating the first fibrous layer including the fibers ( 1 ) and the second fibrous layer including the heat fusible fibers ( 2 ) and having a MD shrinkage ratio that is lower by 5% or more than a MD shrinkage ratio of the first fibrous layer; integrating the first fibrous layer and the second fibrous layer by partial entanglement of the fibers ( 1 ) included in the first fibrous layer and the fibers ( 2 ) included in the second fibrous layer at an interface between the first fibrous layer and the second fibrous layer in a thickness direction of the nonwoven fabric, such that entanglements and regions between the entanglements are formed; shrinking the first fibrous layer to form a structure in which the second fibrous layer is raised in a thickness direction at the regions between the entanglements; and partially applying the sonic bond processing to the first and second fibrous layers from a side of the second fibrous layer after the entanglement and shrinkage, wherein the entanglement and shrinkage are simultaneously achieved by increasing a temperature to a level in which helical crimps are developed in fibers ( 1 ) or to a higher level, and the fibers ( 1 ) develop helical crimps and shrink so as to tangle the fibers ( 2 ) included in the second fibrous layer.

Assignees

• Terada Hirokazu
• Jnc Corp
• Jnc Fibers Corp

Inventors

• Terada Hirokazu

Classifications

• B32B2250/02

  2 layers · CPC title

• Y10T428/24322

  Composite web or sheet · CPC title

• D04H1/50

  by treatment to produce shrinking, swelling, crimping or curling of fibres (in combination with needling D04H1/482) · CPC title

• B32B3/263

  characterised by a layer having non-uniform thickness · CPC title

• B32B5/26

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title