JP3948781B2 - Short fiber nonwoven fabric and method for producing the same - Google Patents
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Description
【０００１】
【発明の属する技術分野】
本発明は、短繊維不織布及びその製造方法に関するものであり、特に構成繊維が三次元的交絡を有して嵩高性と機械的特性とを併せもつ短繊維不織布及びその製造方法に関するものである。
【０００２】
【従来の技術】
従来より、嵩高性を有する不織布としては、太繊度の短繊維を三次元的に交絡させた不織布が知られている。しかしながら、太繊度の短繊維を三次元的に交絡させた不織布は、嵩高性は優れているものの、構成繊維の曲げモーメントが大きいため構成繊維同士の交絡度合いが小さくなり、機械的強力に劣るとともに不織布表面の粗硬感が強いという問題があった。
【０００３】
太繊度の短繊維同士を三次元的に交絡させるためには、一般に高圧液体流処理を行う。高圧液体流処理による太繊度の短繊維同士の交絡度合いを上げるためには、例えば水圧をあげて処理を行う方法や、あるいは処理回数を増やす方法等が挙げられるが、このような処理方法は繊維への水圧による打撃が大きく、ひどいときには繊維の切断等が生じるといった問題があった。さらには、多大なエネルギーが必要となり経済的にも生産コストが高くなりやすいなどの問題があった。
【０００４】
【発明が解決しようとする課題】
本発明は、このような問題を解決するもので、優れた不織布強力と嵩高性とを有する短繊維不織布およびその製造方法を提供するものである。さらに、三次元的交絡処理を容易に行えるようにし、また不織布表面の粗硬感を低減させるものである。
【０００５】
【課題を解決するための手段】
本発明者らは上記課題を解決すべく鋭意検討を行った結果、太繊度の短繊維と細繊度の短繊維とを一定量で混綿した短繊維不織ウエブに三次元的交絡処理を行うと、得られた短繊維不織布は実用的な機械的強力を有し、かつ嵩高性をも併せ持つことを見い出した。本発明はこの知見に基づくものであり、以下の構成を要旨とするものである。
【０００６】
（１）構成繊維が細繊度短繊維と太繊度短繊維とからなり、細繊度短繊維の単糸繊度が０．１〜２デニールであり、太繊度短繊維の単糸繊度が３〜２５デニールであり、細繊度短繊維と太繊度短繊維との単糸繊度比率が（太繊度短繊維の単糸繊度）／（細繊度短繊維の単糸繊度）＝３〜５０であり、前記構成繊維同士が高圧液体流処理にもとづく三次元的交絡により一体化しており、前記三次元的交絡は、細繊度短繊維が太繊度短繊維に絡まりついて太繊度短繊維同士を繋ぎあっているとともに、細繊度短繊維同士も交絡したものであることを特徴とする短繊維不織布。
【０００７】
この構成によると、太繊度短繊維と細繊度短繊維とを混綿することで、不織布強力と嵩高性とに優れた短繊維不織布が得られるとともに、細繊度短繊維が太繊度短繊維に絡み付くことで、太繊度短繊維同士を繋ぎあわせることができ、細繊度短繊維同士が絡み合うことで不織布強力と表面平滑性に優れた短繊維不織布とすることができる。
（２）細繊度短繊維と太繊度短繊維との混繊比率が重量比で（細繊度短繊維）：（太繊度短繊維）＝２０：８０〜８０：２０であることを特徴とする短繊維不織布。
【０００８】
この構成によると、細繊度短繊維と太繊度短繊維との混繊比率を上記の範囲とすることで、不織布強力と嵩高性とを合わせ持つ短繊維不織布を得ることができる。
【０００９】
（３）嵩密度が０．０８ｇ／ｃｍ3 以下であることを特徴とする短繊維不織布。
嵩密度は嵩高性の指標であり、本発明においては、嵩密度が０．０８ｇ／ｃｍ3 以下であるものを嵩高性を有する短繊維不織布とする。
【００１２】
（４）単糸繊度が０．１〜２デニールの細繊度短繊維と単糸繊度が３〜２５の太繊度短繊維とを、単糸繊度比率が（太繊度短繊維の単糸繊度）／（細繊度短繊維の単糸繊度）＝３〜５０となるように混綿して不織ウエブを形成し、この不織ウエブの構成繊維に高圧液体流処理により三次元的交絡を付与することで、細繊度短繊維を太繊度短繊維に絡まりつかせて太繊度短繊維同士を繋ぎあわせるとともに、細繊度短繊維同士も交絡させて、ウエブを一体化させることを特徴とする短繊維不織布の製造方法。
【００１３】
この製造方法によると、不織布強力に優れ、しかも嵩高性を有する短繊維不織布を形成することができるのみならず、高圧液体流処理により三次元的交絡を付与するため、細繊度短繊維が太繊度短繊維に絡み付くことで太繊度短繊維同士を繋ぎあわせることができ、また細繊度短繊維同士が絡み合うことで不織布強力と表面平滑性に優れた短繊維不織布とすることができる。
【００１４】
【発明の実施の形態および作用】
まず、本発明の短繊維不織布を構成する短繊維について説明する。
本発明において適用される短繊維は、繊維形成性を有する熱可塑性樹脂、すなわち、主にエステル系重合体、アミド系重合体、オレフィン系重合体からなるものである。
【００１５】
エステル系重合体としては、テレフタル酸、イソフタル酸、ナフタリン−２，６−ジカルボン酸等の芳香族ジカルボン酸、あるいはアジピン酸、セバチン酸等の脂肪族ジカルボン酸又はこれらのエステル類を酸成分とし、かつエチレングリコール、ジエチレングリコール、１，４−ブタジオール、ネオペンテングリコール、シクロヘキサン−１，４−メタノール等のジオール化合物をエステル成分とするホモポリエステル重合体あるいは共重合体が挙げられる。なお、これらのポリエステル系重合体には、パラオキシ安息香酸、５−ソジウムスルホイソフタール酸、ポリアルキレングリコール、ペンタリストール、ビスフェノールＡ等が添加あるいは共重合されていてもよい。
【００１６】
アミド系重合体としてはポリイミノ−１−オキソテトラメチレン（ナイロン４）、ポリテトラメチレンアジパミド（ナイロン４６）、ポリカプラミド（ナイロン６）、ポリヘキサメチレンアジパミド（ナイロン６６）、ポリウデカナミド（ナイロン１１）、ポリラウロラクタミド（ナイロン１２）、ポリメタキシレンアジパミド、ポリパラキシリレンデカナミド、ポリビスシクロヘキシルメタンデカナミドまたはこれらのモノマを構成単位とするポリアミド系重合体が挙げられる。特に、ポリテトラメチレンアジパミドの場合、ポリテトラメチレンアジパミドにポリカプラミドやポリヘキサメチレンアジパミド、ポリウンデカメチレンテレフタラミドなどの他のポリアミド成分が３０モル％以下で共重合されたポリテトラメチレンアジパミド系共重合体であってもよい。
【００１７】
オレフィン系重合体としては炭素原子数２〜１８の脂肪族α−モノオレフィン、例えば、エチレン、プロピレン、ブテン− 1、ドデセン− 1、オクタデセン− 1からなるホモポリオレフィン重合体が挙げられる。この脂肪族α−モノオレフィンは、他のエチレン系不飽和モノマー、例えばブタジエン、イソプレン、ペンタジエン−１，３、スチレン、α−メチルスチレンのような類似のエチレン系不飽和モノマーが共重合されたポリオレフィン系共重合体であってもよい。また、ポリエチレン系重合体の場合には、エチレンに対してプロピレン、ブテン− 1、ヘキセン− 1、オクテン− 1または類似の高級α−オレフィンが10重量％以下共重合されたものであってもよく、ポリプロピレン系重合体の場合には、プロピレンに対してエチレンまた類似の高級α−オレフィンが10重量％以下で共重合されたものであってもよい。
【００１８】
尚、本発明においては、前述の熱可塑性樹脂に、必要に応じて、例えば艶消し剤、潤滑剤、顔料、熱安定剤、耐光剤、紫外線吸収剤、制電剤、導電剤、蓄熱剤などの各種添加剤を適宜の範囲内で添加することができる。
【００１９】
次に、本発明の短繊維不織布について説明する。
本発明の短繊維不織布は、構成繊維が細繊度短繊維と太繊度短繊維とからなり、細繊度短繊維の単糸繊度が０．１〜２デニールであり、太繊度短繊維の単糸繊度が３〜２５デニールであり、細繊度短繊維と太繊度短繊維との単糸繊度比率が（太繊度短繊維の単糸繊度）／（細繊度短繊維の単糸繊度）＝３〜５０であり、前記構成繊維同士が高圧液体流処理により三次元的交絡により一体化しており、前記三次元的交絡は、細繊度短繊維が太繊度短繊維に絡まりついて太繊度短繊維同士を繋ぎあっているとともに、細繊度短繊維同士も交絡した構成を有するものである。
【００２０】
本発明においては、単糸繊度比率を、「単糸繊度比率＝（太繊度短繊維の単糸繊度）／（細繊度短繊維の単糸繊度）」として定義する。
本発明の短繊維不織布を構成する細繊度短繊維は、その単糸繊度が０．１〜２デニールである必要がある。単糸繊度が０. １デニール未満であると生産性や操業性に劣るため好ましくなく、逆に単糸繊度が２デニールを越えると、細繊度短繊維同士の交絡度合いは良好であるものの太繊度短繊維に細繊度短繊維が絡みつく効果が薄れ、機械的強力に劣ることとなり本発明の目的とするものが得られない。
【００２１】
従って、本発明においては細繊度短繊維の単糸繊度は０．１〜２デニールであることが必要であり、特に０．２〜１．５デニールであるものが好適に使用できる。
【００２２】
細繊度短繊維を得る方法としては、直接紡糸法により得る方法や、海島型二成分系複合繊維を用いて海部を溶剤により溶かし島部で構成される細繊度短繊維を得る方法や、前記の海島型二成分系複合繊維において海部を衝撃により破壊して島部で構成される細繊度短繊維を得る方法や、あるいは分割型二成分系複合繊維を用いてカード機にかけてその衝撃により分割割繊する方法や、分割型二成分系複合繊維において３次元交絡処理の際の高圧液体流の衝撃により分割割繊して細繊度短繊維を得る方法等が挙げられる。
【００２３】
一方、本発明の短繊維不織布を構成する太繊度短繊維は、その単糸繊度が３〜２５デニールである必要がある。単糸繊度が２５デニールを越えると、高圧液体流処理等の三次元的交絡付与工程において、高エネルギーを付加しても太繊度短繊維が変形しにくくなり、細繊度短繊維が混在しているとはいうものの、繊維同士を緻密に一体化させることが困難となる。従って、得られる不織布は、嵩高性には優れるものの機械的強力に著しく劣り本発明の目的とするものではなくなる。また、単糸繊度が３デニール未満であると、嵩高性に優れた不織布を得ることができない。
【００２４】
従って、太繊度短繊維の単糸繊度は３〜２５デニールであることが必要であり、特に５〜２０デニールであるものが好適に使用できる。
本発明の短繊維不織布を構成する細繊度短繊維と太繊度短繊維との単糸繊度比率は、３〜５０とする必要がある。単糸繊度比率が３未満であると、細繊度短繊維と太繊度短繊維との繊度差があまりに小さくなり、機械的強力には優れるものの嵩高性が付与できないことになる。逆に、単糸繊度比率が５０を越えると、繊度差があまりに大きくなり不織ウエブの作成時において混綿度合いの均整度に劣るだけでなく、細繊度短繊維と太繊度短繊維との曲げモーメントの差が大きいために細繊度短繊維が太繊度短繊維に絡みつきにくくなり、得られる不織布の地合い及び機械的強力に劣るものなる。
【００２５】
従って、細繊度短繊維と太繊度短繊維との単糸繊度比率は３〜５０であることが必要であり、上記の理由から単糸繊度比率を４〜４０とすることが特に好ましい。
【００２６】
また、細繊度短繊維と太繊度短繊維との混綿比率は、重量比で（細繊度短繊維）：（太繊度短繊維）＝２０：８０〜８０：２０であるのが好ましい。細繊度短繊維の混綿比率が２０重量％未満であると、不織布を構成する太繊度短繊維の割合が多くなるため、水流交絡による三次元交絡度合いが低く、得られる不織布は嵩高性には優れるものの機械的強力が十分でなくなる。逆に細繊度短繊維の混綿比率が８０重量％を越えると、不織布の機械的強力及び不織布表面の平滑性には優れているものの嵩高性が十分でなくなる。
【００２７】
従って、細繊度短繊維と太繊度短繊維との混綿比率は、重量比で２０：８０〜８０：２０であるのが好ましく、さらに好ましくは３０：７０〜７０：３０である。
【００２８】
本発明の短繊維不織布の嵩密度は、０．０８ｇ／ｃｍ3 以下であることが好ましく、さらに好ましくは０．０７ｇ／ｃｍ3 以下である。
嵩密度は嵩高性の指標となるものであり、嵩密度が０．０８ｇ／ｃｍ3 以下であると、本発明の短繊維不織布として十分な嵩高性を有するものとして扱えるが、嵩密度が０．０８ｇ／ｃｍ3 よりも大きくなると、嵩高性に劣るものとなり好ましくない。
【００２９】
本発明の不織布の目付は、２０〜１５０ｇ/ ｍ2 であることが好ましい。目付が２０ｇ/ ｍ2 より小さいと、不織ウエブの作成時にハンドリングの良好性が低下するとともに、地合いに優れる不織布が得られにくい傾向にある。逆に、目付が１５０ｇ／ｍ2 より大きいと、高圧液体流処理を施す際の加工エネルギーが大きくなり、場合によっては不織ウエブの内層において構成繊維同士に十分な交絡がなされず、機械的強力の低い不織布となりやすい。
【００３０】
そのため、本発明の不織布の目付は２０〜１５０ｇ/ ｍ2 であれば好ましいが、特に３０〜１００ｇ／ｍ2 の範囲であることが好ましい。
本発明の不織布を構成する細繊度短繊維および太繊度短繊維の繊維断面は、熱可塑性樹脂単体の丸断面に限定されるものではなく、単体中空断面や単体多葉断面、あるいは２種類の熱可塑性樹脂からなる芯鞘複合断面や並列型複合断面や並列型中空複合断面が適用できる。特に、太繊度短繊維の繊維断面を中空断面にすれば不織布の嵩高性をさらに高めることができる。
【００３１】
次に本発明の短繊維不織布の製造方法について説明する。
本発明の方法では、まず、細繊度短繊維の単糸繊度が０．１〜２デニールであり、太繊度短繊維の単糸繊度が３〜２５デニールであり、細繊度短繊維と太繊度短繊維との単糸繊度比率が（太繊度短繊維の単糸繊度）／（細繊度短繊維の単糸繊度）＝３〜５０である細繊度短繊維と太繊度短繊維とを混綿する。この時の混綿比率は、重量比で２０：８０〜８０：２０となるように混綿することが好適である。次に混合綿をカード機を用いて開繊及び集積して所定の目付の不織ウエブを作成する。この不織ウエブは、構成繊維の配列度合いによってカード機の進行方向に配列したパラレルウエブ、パラレルウエブのクロスレイドされたウエブ、ランダムに配列したランダムウエブ、あるいは両者の中程度に配列したセミランダムウエブのいずれでもよく、用途によって適宜選択すればよい。
【００３２】
次に、得られた不織ウエブの構成繊維同士を三次元的に交絡させる。この三次元交絡処理としては高圧液体流処理を用いる。この高圧液体流処理を施すに際しては公知の方法を採用することができる。
【００３３】
例えば、孔径が０. ０５〜１. ５ｍｍの噴射孔を噴射孔間隔０. ０５〜５ｍｍで１列ないしは複数列に多数配したオリフィスヘッドから、移動する多孔性支持部材上に載置した不織ウエブに高圧液体流を噴射させる。
【００３４】
高圧液体流としては、常温の水あるいは熱水を使用することができる。高圧液体流を前記不織ウエブに衝突させるに際しては、多孔性支持部材の進行方向に対して直角をなす方向に噴射ノズルを振動させて高圧液体流を均一に衝突させるとよい。この高圧液体流噴射の際に用いられる多孔性支持部材の材質としては、不織ウエブと支持部材との積層された部分を高圧液体流が通過しうる構成のものであれば、金属製・ポリエステル製あるいはその他の材質でもよい。
【００３５】
この高圧液体流による交絡処理は、２段階に分けて作用させるとよい。第１段階の処理では、前記不織ウエブに一定の水圧、例えば４０ｋｇ／ｃｍ2 よりも小さい低水圧で液体流を噴射させて予備交絡処理を行う。この予備交絡処理における高圧液体流の水圧が前記水圧値よりも高いと、高圧液体流の噴射により発生する随伴気流により前記ウエブの乱れが生じ、目付け斑となるため不織布の品位上好ましくない。第２段階の処理では、第１段階の処理水圧よりも高水圧、好ましくは水圧が５０ｋｇ／ｃｍ2 以上の高水圧を施す。この時の水圧が第１段階の処理水圧より低いと、構成繊維同士が十分に交絡されず、得られた不織布の引張強力等の機械的特性が低下する。第１段階の処理水圧よりも高水圧の高圧液体流の噴射により交絡処理を行うことによって、前記第１段階の予備交絡処理の施された不織ウエブの構成短繊維同士を相互に三次元的に交絡させ、機械的強力に優れた不織布が得られるのである。
【００３６】
なお、第２段階の処理では、まずウエブの表側から処理を施した後にウエブを反転し、同じ水圧で裏側に交絡処理を施すことにより、表裏ともにより一層緻密に交絡した不織布を得ることができる。
【００３７】
高圧液体流処理を施した後、ウエブから過剰水分を除去する。この過剰水分を除去するに際しては、公知の方法を採用することができる。例えばマングルロール等の水分除去装置を用いて過剰水分をある程度除去し、引き続きサクションバンド方式の熱風循環乾燥機等の乾燥装置を用いて残余の水分を除去することが挙げられる。
【００３８】
上述のような高圧液体流処理を不織ウエブに施すと、太繊度短繊維は高圧液体流の影響を受けても倦縮形態を維持するため、短繊維不織布が嵩高性を有するようになる。細繊度短繊維は高圧液体流により太繊度短繊維に絡まりついて太繊度短繊維同士を繋ぎあい、また細繊度短繊維同士も交絡して機械的強力と表面平滑性とを付与するようになる。
【００３９】
すなわち、本発明によると、短繊維不織布を太繊度短繊維と細繊度短繊維とで形成することで、細繊度短繊維により短繊維不織布に機械的強力及び不織布表面の平滑性が付加され、太繊度短繊維によって嵩高性が付加される。しかも、細繊度短繊維が太繊度短繊維に三次元的に交絡するとともに、細繊度短繊維同士も三次元的に交絡して緻密に一体化し、嵩高性と機械的強力とを併せ持つ短繊維不織布が得られるのである。
【００４０】
また、三次元的交絡処理により、太繊度短繊維に細繊度短繊維を絡まりつかせることで太繊度短繊維同士を繋ぎ合わせ、不織ウエブを一体化しているため、太繊度短繊維同士を三次元的に交絡させる場合に比べて、容易に構成繊維同士を交絡させることができる。
【００４１】
さらに細繊度短繊維が太繊度短繊維に三次元的に交絡することで、不織布の表面においても太繊度短繊維に細繊度短繊維が絡まっており、特に不織布の表面に細繊度短繊維が存在しているため、表面の粗硬感を和らげることができる。
【００４２】
【実施例】
次に、実施例に基づき本発明を具体的に説明するが、本発明はこれらの実施例によって何ら限定されるものではない。
【００４３】
以下の実施例において、不織布の物性値の測定は次の方法で行った。
（１）目付（ｇ／ｍ2 ）：試料として幅１０ｃｍ、長さ１０ｃｍの試験片を５個作成し、その重量を測定してその平均値を目付とした。
（２）引張り強力（ｋｇ／５ｃｍ幅）：試料として幅５ｃｍ、長さ１５ｃｍの試験片を１０個作成し、東洋ボールドウィン社製テンシロンＵＴＭ−４−１−１００を用いて、つかみ間隔１０ｃｍ、引張速度１０ｃｍ／分の条件で各試験片の最大引張り強力を個々に測定し、その平均値を引張強力とした。
（３）嵩密度（ｇ／ｃｃ）：嵩密度は以下の式により定義した。
【００４４】
嵩密度（ｇ／ｃｃ）＝（目付［ｇ／ｍ2］）／（厚み［ｍｍ］）／１０００
すなわち、幅１０ｃｍ、長さ１０ｃｍの試験片を５個作成し、大栄化学精機製作所（株）製の厚み測定器により４．５ｇ／ｃｍ2 の荷重の印加による個々の不織布の厚みを測定してその平均値を厚みとし、上式の計算方法により得られる値を嵩密度とした。
【００４５】
（実施例１）
細繊度短繊維として、単糸繊度０．７デニール、繊維長３８ｍｍ、繊維断面が中実丸断面である日本エステル（株）製のポリエステル短繊維を用いた。一方、太繊度短繊維として、単糸繊度３デニール、繊維長５１ｍｍ、繊維断面が中実丸断面である日本エステル（株）製のポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は４．３であった。
【００４６】
上記の細繊度短繊維と太繊度短繊維とを重量比で５０：５０の割合で混綿し、パラレルカード機にて不織ウエブを得た。次いで、この不織ウエブを移動する１００メッシュの金属製ネット上に載置して高圧液体流処理を施した。高圧液体流処理の条件は、噴射孔径０．１ｍｍ、噴射孔間隔０．６ｍｍで一列に配置された高圧柱状水流処理装置を用い、ウエブ上方５０ｍｍの位置から２段階に分けて柱状水流を作用させた。第１段階の処理では水圧３０ｋｇ／ｃｍ2 の常温の水により高圧液体流を作用させ予備交絡を施した。第２段階の処理では水圧を６０ｋｇ／ｃｍ2 とした。なお、第２段階の処理では、まずウエブの表側から５回施した後にウエブを反転し、裏側から５回施した。
【００４７】
次いで、得られた処理物からマングルロールを用いて余剰の水分を除去した後、温度１１０℃の乾燥機により乾燥処理を行った。これにより、繊維同士が緻密に三次元的交絡をした目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００４８】
【表１】
（実施例２）
細繊度短繊維として実施例１と同一の単糸繊度０．７デニールのポリエステル短繊維を用いた。一方、太繊度短繊維として単糸繊度６デニール、繊維長５１ｍｍ、繊維断面が並列型中空複合断面である日本エステル（株）製のポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は８．６であった。そして、それ以外は実施例１と同様にして目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００５０】
（実施例３）
細繊度短繊維として、実施例１と同一の単糸繊度０．７デニールのポリエステル短繊維を用いた。一方、太繊度短繊維としては単糸繊度１０デニール、繊維長５１ｍｍ、繊維断面が並列型中空複合断面である日本エステル（株）製のポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は１８．６であった。そして、それ以外は実施例１と同様にして目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００５１】
（実施例４）
細繊度短繊維として、単糸繊度１．３デニール、繊維長３８ｍｍ、繊維断面が中実丸断面である日本エステル（株）製のポリエステル短繊維を用いた。一方、太繊度短繊維として、実施例２と同一の単糸繊度６デニール、繊維長５１ｍｍのポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は４．６であった。そして、それ以外は実施例１と同様にして目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００５２】
（実施例５）
細繊度短繊維として、実施例４と同一の単糸繊度１．３デニールのポリエステル短繊維を用いた。一方、太繊度短繊維として、単糸繊度１３デニールのポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は１０．０であった。それ以外は実施例１と同様にして目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００５３】
（実施例６）
細繊度短繊維として、実施例４と同一の単糸繊度１．３デニールのポリエステル短繊維を用いた。一方、太繊度短繊維として、単糸繊度２０デニール、繊維長７６ｍｍ、繊維断面が並列型中空複合断面である日本エステル（株）製のポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は１５．４であった。それ以外は実施例１と同様にして目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００５４】
（実施例７）
細繊度短繊維と太繊度短繊維との混綿比率を重量比で（細繊度短繊維）：（太繊度短繊維）＝２５：７５とした以外は実施例１と同様にして目付４０ｇ／ｍ2の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００５５】
（実施例８）
細繊度短繊維と太繊度短繊維との混綿比率を重量比で（細繊度短繊維）：（太繊度短繊維）＝７５：２５とした以外は実施例１と同様にして目付４０ｇ／ｍ2の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
得られた不織布の製造条件と物性とを表１に示す。
【００５６】
（実施例９）
細繊度短繊維として、ポリエチレンとポリエチレンテレフタレートとからなり、断面構造が図１に示すような形状の分割型複合断面よりなる短繊維を用いた。
【００５７】
細繊度短繊維は下記のごとく製造した。すなわち、融点が１３０℃でメルトインデックス値（ＡＳＴＭ−Ｄ−１２３８（Ｅ）法で測定）が２５ｇ／１０分の高密度ポリエチレン１と、融点が２５６℃で、フェノール：テトラクロルエタン＝１：１の混合溶媒中２０℃で測定した極限粘度が０．６４のポリエチレンテレフタレート２とを用い、繊維断面形状が図１（分割数＝１２）のようになる口金を介して複合比が５０／５０重量％、単孔吐出量が０．８９ｇ／分の条件にて溶融紡出した。該紡出糸条を公知の冷却装置にて冷却した後、油剤を付与し、速度が１０００ｍ／分の引取りロールを介して未延伸糸として巻き取った。該未延伸糸を複数本引き揃え未延伸糸トウとした。該未延伸トウを周速の異なるロール間で延伸倍率が２．８倍の条件で延伸を行った。次いで、押し込み式クリンパーにて倦縮を付与した後、繊維長を５１ｍｍに切断し短繊維を得た。得られた短繊維の繊度は３デニールであった。
【００５８】
未割繊の該細繊度短繊維と実施例３に用いた繊度１０デニールの太繊度のポリエステル短繊維を用い、混綿比を５０／５０重量％とし、パラレルカード機にて不織ウエブを得た。次いで、乾燥温度を１００℃としたこと以外は実施例１と同一条件下で繊維同士が緻密に三次元交絡した目付けが４０ｇ／ｍ2 の短繊維不織布を得た。得られた不織布を顕微鏡にて観察した結果、高圧液体流処理によって細繊度短繊維の構成素材であるポリエチレン１とポリエチレンテレフタレート２とが割繊されており、これらの割繊された短繊維は太繊度ポリエステル短繊維に絡みついていた。
【００５９】
また、割繊後のポリエチレン１とポリエチレンテレフタレート２との単糸繊度は各々０．２５デニールであり、細繊度短繊維と太繊度短繊維の単糸繊度比率は４０であった。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００６０】
（比較例１）
細繊度短繊維として、実施例４と同一の単糸繊度１. ３デニールのポリエステル短繊維を用いた。一方、太繊度短繊維として実施例１と同一の単糸繊度３デニールのポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は２．３であった。 前記細繊度短繊維と太繊度短繊維とを重量比で５０：５０の割合で混綿し、実施例１と同様にして目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００６１】
（比較例２）
細繊度短繊維として、実施例１と同一の単糸繊度０．７デニールのポリエステル短繊維を用いた。一方、太繊度短繊維として単糸繊度３０デニールのポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は４２．９であった。
【００６２】
前記細繊度短繊維と太繊度短繊維を重量比で５０：５０の割合で混綿し、実施例１と同一条件下にて、目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００６３】
（比較例３）
細繊度短繊維として、単糸繊度３デニールのポリエステル短繊維を用い、太繊度短繊維として、単糸繊度１３デニールのポリエステル短繊維を用いた。細繊度短繊維と太繊度短繊維との単糸繊度比率は４．３であった。
【００６４】
前記細繊度短繊維と太繊度短繊維を重量比で５０：５０の割合で混綿し、実施例１と同一条件下にて、目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００６５】
（比較例４）
実施例１と同一の繊度０．７デニールのポリエステル短繊維単体にしたこと以外は、実施例１と同一条件下にて、目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
得られた不織布の製造条件と物性とを表１に示す。
【００６６】
（比較例５）
単糸繊度１３デニールのポリエステル短繊維単体にしたこと以外は、実施例１と同一条件下にて、目付４０ｇ／ｍ2 の短繊維不織布を得た。構成繊維の特性と得られた不織布の物性とを表１に示す。
【００６７】
実施例１，２で得られた不織布は、本発明の短繊維不織布であるので、機械的特性としての不織布強力及び嵩高性に優れるものであった。
実施例３で得られた不織布は、太繊度短繊維の単糸繊度を実施例１，２より大きくしたので、嵩高性にさらに優れるものであった。
【００６８】
実施例４，５，６で得られた不織布は、細繊度短繊維及び太繊度短繊維の単糸繊度を実施例１よりも大きくしたため、嵩高性にさらに優れるものとなった。
実施例７で得られた不織布は、太繊度短繊維の混綿比率を実施例１より大きくしたので、嵩高性にはさらに優れるものであった。
【００６９】
実施例８で得られた不織布は、細繊度短繊維の混綿比率を実施例１より大きくしたため、不織布の表面平滑性に優れ、不織布強力にはさらに優れるものであった。
【００７０】
実施例９で得られた不織布は、太繊度短繊維の単糸繊度をを実施例１よりも大きくしたので、嵩高性にさらに優れるものであった。また、実施例９では、他の実施例とは異なり、細繊度短繊維として分割型複合断面よりなる短繊維を割繊して得られた短繊維を用いたが、他の実施例と同様に不織布強力と嵩高性に優れた短繊維不織布が得られた。
【００７１】
比較例１で得られた不織布は、単糸繊度比率が本発明の範囲の下限よりも小さな値であったので、不織布強力には優れるものの嵩高性がなかった。
比較例２で得られた不織布は、太繊度短繊維の単糸繊度が本発明の範囲の上限よりも大きな値であったので、嵩高性には優れるものの不織布強力に著しく劣るものであった。
【００７２】
比較例３で得られた不織布は、細繊度短繊維の単糸繊度が本発明の範囲の上限よりも大きな値であったので、嵩高性には優れるものの不織布強力に著しく劣るものであった。
【００７３】
比較例４で得られた不織布は、細繊度短繊維のみで構成されているため、不織布強力には優れるものの嵩高性のないものであった。
比較例５で得られた不織布は、太繊度短繊維のみで構成されているため、嵩高性には優れるものの不織布強力に著しく劣るものであった。
【００７４】
【発明の効果】
本発明によると、細繊度短繊維の単糸繊度が０．１〜２デニールであり、太繊度短繊維の単糸繊度が３〜２５デニールであり、細繊度短繊維と太繊度短繊維との単糸繊度比率が（太繊度短繊維の単糸繊度）／（細繊度短繊維の単糸繊度）＝３〜５０である細繊度短繊維と太繊度短繊維とを用いて、高圧液体流処理にもとづく三次元的交絡により構成繊維同士を一体化させ、細繊度短繊維が太繊度短繊維に絡まりついて太繊度短繊維同士を繋ぎあっているとともに、細繊度短繊維同士も交絡したものであるようにしたため、不織布強力及び嵩高性に優れ、また表面平滑性に優れた短繊維不織布を得ることができる。
【００７５】
本発明の短繊維不織布は、上記構成よりなるものであり各種用途に好適に用いられる。
例えば、本発明の短繊維不織布は、太繊度短繊維を構成繊維としているので耐摩耗性及び耐久性に優れ、また、細繊度短繊維の緻密な交絡による繊維空隙の小さい部分と太繊度短繊維が緩やかに絡まり合うことによる繊維空隙の大きい部分を併せ持つものである。よって、本発明の短繊維不織布をフィルターやワイパー等として用いると、塵埃等の捕集性能を長期に亘って維持できることが可能となり、また、粗粒子や粗塵を繊維空隙の大きい部分で捕集し、微粒子や微塵を繊維空隙の小さい部分で捕集できるので、一枚の不織布でありながら捕集対象物に応じた分別収拾が可能となる。さらに、細繊度短繊維のみで構成される短繊維不織布に比べて、摩擦係数が小さいために、ストライクスルー性に優れ、家庭用や業務用のフローリングワイパーとして好適に用いられる。
【００７６】
また、嵩高性、保温性等に優れることから、キルティングの中綿、フローリング材や壁材等の緩衝材、吸音材としても好適に用いられる。
また、太繊度短繊維は、倦縮形態を維持した状態で緩やかに絡み合っているので、不織布は程よい伸縮性を有しており、成形用不織布として用いた際、不織布が破れることなく成形型に沿い、かつ細繊度短繊維の緻密な交絡により不織布形態は保持されるので、優れた成形性を有するという効果を奏する。
【図面の簡単な説明】
【図１】本発明の実施例の不織布を構成するための、分割型複合断面よりなる細繊度短繊維の断面図である。
【符号の説明】
１ ポリエチレン
２ ポリエチレンテレフタレート[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a short fiber nonwoven fabric and a method for producing the same, and more particularly to a short fiber nonwoven fabric in which constituent fibers have three-dimensional entanglement and have both bulkiness and mechanical properties, and a method for producing the same.
[0002]
[Prior art]
Conventionally, as a nonwoven fabric having bulkiness, a nonwoven fabric in which short fibers having a large fineness are three-dimensionally entangled is known. However, the nonwoven fabric obtained by entangled short fibers with a large fineness three-dimensionally has excellent bulkiness, but because the bending moment of the constituent fibers is large, the degree of entanglement between the constituent fibers becomes small and the mechanical strength is inferior. There was a problem that the coarseness of the nonwoven fabric surface was strong.
[0003]
In general, high-pressure liquid flow treatment is performed in order to three-dimensionally intertwine short fibers having large fineness. In order to increase the degree of entanglement between short fibers of large fineness by high-pressure liquid flow treatment, for example, there are a method of increasing the water pressure, a method of increasing the number of treatments, and the like. There was a problem that the fiber was severely blown by water pressure, and when it was severe, the fiber was cut. Furthermore, there is a problem that a great amount of energy is required and the production cost tends to be high economically.
[0004]
[Problems to be solved by the invention]
This invention solves such a problem, and provides the short fiber nonwoven fabric which has the outstanding nonwoven fabric strength and bulkiness, and its manufacturing method. Furthermore, the three-dimensional entanglement process can be easily performed, and the coarseness of the nonwoven fabric surface is reduced.
[0005]
[Means for Solving the Problems]
As a result of intensive studies to solve the above problems, the present inventors have performed a three-dimensional entanglement treatment on a short fiber nonwoven web in which a short amount of thick fine fibers and a short fiber of fine fineness are mixed in a certain amount. It has been found that the obtained short fiber nonwoven fabric has practical mechanical strength and also has bulkiness. The present invention is based on this finding and has the following structure.
[0006]
(1)Constituent fiberIt consists of fine fineness short fibers and thick fineness short fibers, the single yarn fineness of the fineness short fibers is 0.1 to 2 denier, the single yarn fineness of the thick fineness short fibers is 3 to 25 denier, and the fineness is short The single yarn fineness ratio of the fiber and the thick fine short fiber is (single fineness of the thick fine short fiber) / (single fineness of the fine fine short fiber) = 3-50,The constituent fibers are integrated by three-dimensional entanglement based on the high-pressure liquid flow treatment, and the three-dimensional entanglement is such that the fine fine short fibers are entangled with the thick fine short fibers and the thick fine short fibers are connected to each other. In addition, the fineness short fibers are entangled with each otherA short fiber nonwoven fabric characterized by that.
[0007]
According to this structure, the short fiber nonwoven fabric excellent in the strength and bulkiness of the nonwoven fabric can be obtained by blending the thick fine fiber and the fine fine fiber.In addition, the fine fiber short fibers are entangled with the thick fine fibers, so that the fine fine fibers can be connected to each other. can do.
(2) The short is characterized in that the mixing ratio of the fine fine short fibers and the thick fine short fibers is (fine fine short fibers) :( thick fine fibers) = 20: 80 to 80:20 by weight ratio. Fiber nonwoven fabric.
[0008]
According to this structure, the short fiber nonwoven fabric which has both nonwoven fabric strength and bulkiness can be obtained by making the blend ratio of the fine fine fiber and the thick fine fiber within the above range.
[0009]
(3) Bulk density is 0.08 g / cmThree A short fiber nonwoven fabric characterized by:
The bulk density is an index of bulkiness. In the present invention, the bulk density is 0.08 g / cm.Three The following is a bulky short fiber nonwoven fabric.
[0012]
(4) A single yarn fineness ratio of a fine fineness short fiber having a single yarn fineness of 0.1 to 2 denier and a thick fineness short fiber having a single yarn fineness of 3 to 25 (single yarn fineness of the thick fineness short fiber) / (Single yarn fineness of the fine fineness short fiber) = 3 to 50, a non-woven web is formed by blending, and the non-woven web is composed of fibers.By giving three-dimensional entanglement by high-pressure liquid flow treatment, the fine fine fibers are entangled with the thick fine fibers, and the fine fine fibers are joined together, and the fine fine fibers are also entangled,A method for producing a short fiber nonwoven fabric, wherein the web is integrated.
[0013]
According to this production method, it is possible to form a short fiber nonwoven fabric having excellent nonwoven fabric strength and bulkiness.Not only the three-dimensional entanglement by high-pressure liquid flow treatment, so that the fine fine fibers can be connected to each other by tangling the fine fine fibers with each other. It can be made into the short fiber nonwoven fabric excellent in nonwoven fabric strength and surface smoothness by entanglement.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
First, the short fiber which comprises the short fiber nonwoven fabric of this invention is demonstrated.
The short fiber applied in the present invention is a thermoplastic resin having a fiber forming property, that is, mainly composed of an ester polymer, an amide polymer, and an olefin polymer.
[0015]
As the ester polymer, aromatic dicarboxylic acid such as terephthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, or aliphatic dicarboxylic acid such as adipic acid or sebacic acid or esters thereof are used as acid components, And the homopolyester polymer or copolymer which uses diol compounds, such as ethylene glycol, diethylene glycol, 1, 4- butadiol, neopentene glycol, and cyclohexane-1, 4-methanol, as an ester component is mentioned. In addition, paraoxybenzoic acid, 5-sodium sulfoisophthalic acid, polyalkylene glycol, pentaristol, bisphenol A, or the like may be added or copolymerized with these polyester polymers.
[0016]
Examples of the amide polymer include polyimino-1-oxotetramethylene (nylon 4), polytetramethylene adipamide (nylon 46), polycoupleramide (nylon 6), polyhexamethylene adipamide (nylon 66), and polyurecanamide (nylon 11). ), Polylaurolactamide (nylon 12), polymetaxylene adipamide, polyparaxylylene decanamide, polybiscyclohexylmethane decanamide, or a polyamide polymer having these monomers as constituent units. In particular, in the case of polytetramethylene adipamide, other polyamide components such as polycoupleramide, polyhexamethylene adipamide, and polyundecamethylene terephthalamide were copolymerized with polytetramethylene adipamide at 30 mol% or less. It may be a polytetramethylene adipamide copolymer.
[0017]
Examples of the olefin polymer include a homopolyolefin polymer comprising an aliphatic α-monoolefin having 2 to 18 carbon atoms, for example, ethylene, propylene, butene-1, dodecene-1, and octadecene-1. This aliphatic α-monoolefin is a polyolefin copolymerized with other ethylenically unsaturated monomers such as butadiene, isoprene, pentadiene-1,3, styrene, α-methylstyrene and similar ethylenically unsaturated monomers. A copolymer may be used. In the case of a polyethylene-based polymer, it may be a copolymer in which 10% by weight or less of propylene, butene-1, hexene-1, octene-1, or a similar higher α-olefin is copolymerized with ethylene. In the case of a polypropylene polymer, ethylene or a similar higher α-olefin may be copolymerized with propylene in an amount of 10% by weight or less.
[0018]
In the present invention, the above-mentioned thermoplastic resin may be added to the above-described thermoplastic resin as necessary, for example, a matting agent, a lubricant, a pigment, a heat stabilizer, a light stabilizer, an ultraviolet absorber, an antistatic agent, a conductive agent, a heat storage agent, and the like. These various additives can be added within an appropriate range.
[0019]
Next, the short fiber nonwoven fabric of the present invention will be described.
The short fiber nonwoven fabric of the present invention is composed of a fine fine fiber and a thick fine fiber, the single fineness of the fine fine fiber is 0.1 to 2 denier, and the single fineness of the thick fine fiber. Is 3 to 25 deniers, and the single yarn fineness ratio of the fine fine short fibers and the thick fine short fibers is (single fineness of the thick fine short fibers) / (single fineness of the fine fine fibers) = 3-50 Yes,The constituent fibers are integrated by three-dimensional entanglement by high-pressure liquid flow treatment, and the three-dimensional entanglement is such that the fine fine short fibers are entangled with the thick fine short fibers and the thick fine short fibers are connected to each other. In addition, the fineness short fibers are also entangled with each other.
[0020]
In the present invention, the single yarn fineness ratio is defined as “single yarn fineness ratio = (single yarn fineness of short fine fiber) / (single yarn fineness of fine fine fiber)”.
The fineness short fiber constituting the short fiber nonwoven fabric of the present invention needs to have a single yarn fineness of 0.1 to 2 denier. If the single yarn fineness is less than 0.1 denier, it is not preferable because it is inferior in productivity and operability. Conversely, if the single yarn fineness exceeds 2 denier, the fineness of the fine fibers and the short fibers are good, but the fineness is fine. The effect that the fine fibers are entangled with the short fibers is weakened and the mechanical strength is inferior, and the object of the present invention cannot be obtained.
[0021]
Accordingly, in the present invention, it is necessary that the single yarn fineness of the fine fine staple fibers is 0.1 to 2 denier, and those having 0.2 to 1.5 denier can be preferably used.
[0022]
As a method for obtaining a fine fine fiber, a method obtained by a direct spinning method, a method for obtaining a fine fine fiber composed of island parts by dissolving the sea part with a solvent using a sea-island type two-component composite fiber, In the sea-island type bicomponent composite fiber, the sea part is broken by impact to obtain fine fibers with short fineness composed of islands, or split type split fiber by impact on a card machine using split type bicomponent composite fiber And a method of dividing and splitting a split type bicomponent composite fiber by impact of a high-pressure liquid flow during a three-dimensional entanglement process to obtain a fineness short fiber.
[0023]
On the other hand, the thick fine fiber constituting the short fiber nonwoven fabric of the present invention needs to have a single yarn fineness of 3 to 25 denier. When the single yarn fineness exceeds 25 deniers, in the three-dimensional entanglement imparting process such as high-pressure liquid flow treatment, even if high energy is applied, the thick fine staple fibers are not easily deformed, and the fine fine staple fibers are mixed. Nevertheless, it becomes difficult to closely integrate the fibers. Therefore, although the obtained nonwoven fabric is excellent in bulkiness, it is remarkably inferior in mechanical strength and is not the object of the present invention. Moreover, the nonwoven fabric excellent in bulkiness cannot be obtained as the single yarn fineness is less than 3 denier.
[0024]
Accordingly, it is necessary that the single yarn fineness of the thick fine short fibers is 3 to 25 denier, and particularly those having 5 to 20 denier can be suitably used.
The single yarn fineness ratio of the fine fine fiber and the thick fine fiber constituting the short fiber nonwoven fabric of the present invention needs to be 3-50. When the single yarn fineness ratio is less than 3, the fineness difference between the fine fine fiber and the thick fine fiber becomes too small, and the bulkiness cannot be imparted although the mechanical strength is excellent. On the other hand, if the single yarn fineness ratio exceeds 50, the fineness difference becomes so large that not only the degree of blending is inferior when creating a nonwoven web, but also the bending moment between the fine fine fiber and the short fine fiber. Because of the large difference, the fine fineness short fibers are less likely to be entangled with the thick fineness short fibers, and the texture and mechanical strength of the resulting nonwoven fabric are poor.
[0025]
Therefore, the single yarn fineness ratio between the fine fine fiber and the thick fine fiber needs to be 3 to 50, and the single yarn fineness ratio is particularly preferably 4 to 40 for the above reasons.
[0026]
Moreover, it is preferable that the blend ratio of the fine fine staple fiber and the thick fine staple fiber is (fine fine staple short fiber) :( large fine fine staple fiber) = 20: 80 to 80:20 by weight ratio. When the blending ratio of the fine fineness short fibers is less than 20% by weight, the proportion of the thick fineness short fibers constituting the nonwoven fabric increases, so the degree of three-dimensional entanglement by hydroentanglement is low, and the resulting nonwoven fabric is excellent in bulkiness. The mechanical strength of things becomes insufficient. On the contrary, if the blending ratio of the fine fineness short fibers exceeds 80% by weight, the mechanical strength of the nonwoven fabric and the smoothness of the nonwoven fabric surface are excellent, but the bulkiness becomes insufficient.
[0027]
Therefore, the blending ratio of the fine fine staple fibers and the thick fine staple fibers is preferably 20:80 to 80:20, more preferably 30:70 to 70:30, by weight.
[0028]
The bulk density of the short fiber nonwoven fabric of the present invention is 0.08 g / cm.Three Or less, more preferably 0.07 g / cm.Three It is as follows.
The bulk density is an index of bulkiness, and the bulk density is 0.08 g / cm.Three When it is below, the short fiber nonwoven fabric of the present invention can be treated as having sufficient bulkiness, but the bulk density is 0.08 g / cm.Three If it is larger than the range, the bulkiness is inferior, which is not preferable.
[0029]
The basis weight of the nonwoven fabric of the present invention is 20 to 150 g / m.2 It is preferable that The basis weight is 20g / m2 If it is smaller than the above, the handling property is deteriorated during the production of the nonwoven web, and a nonwoven fabric excellent in texture tends to be hardly obtained. Conversely, the basis weight is 150 g / m2 If it is larger, the processing energy at the time of performing the high-pressure liquid flow treatment is increased, and in some cases, the constituent fibers are not sufficiently entangled in the inner layer of the nonwoven web, and the nonwoven fabric tends to have low mechanical strength.
[0030]
Therefore, the basis weight of the nonwoven fabric of the present invention is 20 to 150 g / m.2 Is preferable, but in particular 30 to 100 g / m2 It is preferable that it is the range of these.
The fiber cross sections of the fine fine fibers and the thick fine fibers constituting the nonwoven fabric of the present invention are not limited to the round cross section of a single thermoplastic resin, but a single hollow cross section, a single multi-leaf cross section, or two types of heat. A core-sheath composite cross section, a parallel composite cross section, or a parallel hollow composite cross section made of a plastic resin can be applied. In particular, if the fiber cross section of the thick fine short fiber is made to be a hollow cross section, the bulkiness of the nonwoven fabric can be further enhanced.
[0031]
Next, the manufacturing method of the short fiber nonwoven fabric of this invention is demonstrated.
In the method of the present invention, first, the single yarn fineness of the fine fine short fiber is 0.1 to 2 denier, the single yarn fineness of the thick fine short fiber is 3 to 25 denier, and the fine fine short fiber and the thick fine short A fine yarn short fiber and a thick fine fiber having a single yarn fineness ratio to the fiber of (single yarn fineness of the thick fine short fiber) / (single yarn fineness of the fine fine fiber short fiber) = 3 to 50 are mixed. In this case, it is preferable that the blending ratio is 20:80 to 80:20 by weight. Next, the mixed cotton is spread and accumulated using a card machine to create a nonwoven web with a predetermined basis weight. This non-woven web is a parallel web arranged in the direction of travel of the card machine according to the degree of arrangement of the constituent fibers, a cross-laid web of parallel webs, a randomly arranged random web, or a semi-random web arranged in the middle of both. Any of these may be used and may be appropriately selected depending on the application.
[0032]
Next, the constituent fibers of the obtained nonwoven web are entangled three-dimensionally. This three-dimensional entanglement process is a high-pressure liquid flow process.Use. A known method can be employed when performing this high-pressure liquid flow treatment.
[0033]
For example, a nonwoven fabric placed on a moving porous support member from an orifice head in which a plurality of injection holes having a hole diameter of 0.05 to 1.5 mm are arranged in a row or a plurality of rows with a pitch of 0.05 to 5 mm. A high pressure liquid stream is jetted onto the web.
[0034]
As the high-pressure liquid stream, room temperature water or hot water can be used. When the high-pressure liquid flow is caused to collide with the nonwoven web, the injection nozzle is vibrated in a direction perpendicular to the traveling direction of the porous support member so that the high-pressure liquid flow collides uniformly. The material of the porous support member used in this high-pressure liquid flow injection is made of metal / polyester as long as the high-pressure liquid flow can pass through the laminated portion of the nonwoven web and the support member. It may be made of other materials.
[0035]
This entanglement process by the high-pressure liquid flow is preferably performed in two stages. In the first stage treatment, the nonwoven web has a constant water pressure, for example 40 kg / cm.2 The preliminary entanglement process is performed by ejecting the liquid flow at a lower water pressure than the above. If the water pressure of the high-pressure liquid flow in the preliminary entanglement process is higher than the water pressure value, the associated air flow generated by the injection of the high-pressure liquid flow causes disturbance of the web, resulting in spot weight, which is not preferable in terms of the quality of the nonwoven fabric. In the second stage treatment, the water pressure is higher than the first stage treatment water pressure, preferably 50 kg / cm.2 Apply the above high water pressure. If the water pressure at this time is lower than the treatment water pressure in the first stage, the constituent fibers are not sufficiently entangled with each other, and mechanical properties such as tensile strength of the obtained nonwoven fabric are lowered. By performing the entanglement process by jetting a high-pressure liquid flow having a higher water pressure than the treated water pressure in the first stage, the constituent short fibers of the nonwoven web subjected to the preliminary entanglement process in the first stage are three-dimensionally mutually. Thus, a nonwoven fabric excellent in mechanical strength can be obtained.
[0036]
In the second stage treatment, the nonwoven fabric entangled more densely on both the front and back sides can be obtained by first performing the treatment from the front side of the web and then inverting the web and performing the entanglement treatment on the back side with the same water pressure. .
[0037]
After applying the high pressure liquid flow treatment, excess water is removed from the web. In removing this excess water, a known method can be employed. For example, excess moisture is removed to some extent using a moisture removing device such as mangle roll, and then residual moisture is removed using a drying device such as a suction band type hot air circulating dryer.
[0038]
When the non-woven web is subjected to the high-pressure liquid flow treatment as described above, the short-fiber nonwoven fabric comes to be bulky because the thick fine fibers maintain the crimped form even under the influence of the high-pressure liquid flow. The fine fineness short fibers are entangled with the high fineness short fibers by the high-pressure liquid flow to connect the thick fineness short fibers with each other, and the fine fineness short fibers are entangled with each other to impart mechanical strength and surface smoothness.
[0039]
That is, according to the present invention, by forming the short fiber nonwoven fabric with thick fine staple fibers and fine fine staple fibers, the fine fine staple fibers add mechanical strength and non-woven fabric surface smoothness to the short fiber nonwoven fabric. Bulkiness is added by the fine fine fibers. In addition, the short fiber nonwoven fabric has three-dimensional entanglement with fine fine fibers and three-dimensional entanglement between the fine fine fibers and densely integrated, and has both bulkiness and mechanical strength. Is obtained.
[0040]
In addition, the three-dimensional entanglement process entangles the fine fine short fibers with the fine fine short fibers so that the thick fine short fibers are connected to each other and the nonwoven web is integrated. The constituent fibers can be easily entangled compared to the case where they are entangled originally.
[0041]
Furthermore, the fine fine fibers are entangled three-dimensionally with the thick fine fibers, so that the fine fine fibers are entangled with the thick fine fibers even on the surface of the non-woven fabric. Therefore, it is possible to relieve the roughness of the surface.
[0042]
【Example】
EXAMPLES Next, although this invention is demonstrated concretely based on an Example, this invention is not limited at all by these Examples.
[0043]
In the following examples, the physical property values of the nonwoven fabric were measured by the following method.
(1) Weight per unit (g / m2 ): Five test pieces having a width of 10 cm and a length of 10 cm were prepared as samples, and their weights were measured to obtain an average value.
(2) Tensile strength (kg / 5 cm width): Ten test specimens having a width of 5 cm and a length of 15 cm were prepared as samples, and using Tensilon UTM-4-1-100 manufactured by Toyo Baldwin Co., Ltd., the grip interval was 10 cm and the tensile strength was 10 cm. The maximum tensile strength of each test piece was measured individually at a speed of 10 cm / min, and the average value was taken as the tensile strength.
(3) Bulk density (g / cc): The bulk density was defined by the following formula.
[0044]
Bulk density (g / cc) = (weight per unit [g / m2]) / (Thickness [mm]) / 1000
That is, five test pieces having a width of 10 cm and a length of 10 cm were prepared, and 4.5 g / cm was measured with a thickness measuring instrument manufactured by Daiei Chemical Seiki Co., Ltd.2 The thickness of each non-woven fabric by the application of the load was measured, the average value was taken as the thickness, and the value obtained by the above calculation method was taken as the bulk density.
[0045]
Example 1
As the fine fine fiber, a polyester short fiber made by Nippon Ester Co., Ltd. having a single yarn fineness of 0.7 denier, a fiber length of 38 mm, and a fiber cross section having a solid round cross section was used. On the other hand, polyester short fibers made by Nippon Ester Co., Ltd., having a single yarn fineness of 3 denier, a fiber length of 51 mm, and a fiber cross section of a solid round cross section, were used as the thick fine fibers. The single yarn fineness ratio of the fine fine fiber and the thick fine fiber was 4.3.
[0046]
The above fine fine staple fibers and thick fine staple fibers were mixed at a weight ratio of 50:50, and a nonwoven web was obtained using a parallel card machine. The nonwoven web was then placed on a moving 100 mesh metal net and subjected to high pressure liquid flow treatment. The conditions for the high-pressure liquid flow treatment are as follows. Using a high-pressure columnar water treatment device arranged in a row with an injection hole diameter of 0.1 mm and an injection hole interval of 0.6 mm, the columnar water flow is applied in two stages from the position 50 mm above the web. It was. In the first stage treatment, the water pressure is 30 kg / cm.2 Pre-entanglement was performed by applying a high-pressure liquid flow with normal temperature water. In the second stage treatment, the water pressure is 60 kg / cm.2 It was. In the second stage treatment, the web was first applied 5 times from the front side of the web, then the web was inverted and applied 5 times from the back side.
[0047]
Subsequently, excess water was removed from the obtained processed product using mangle roll, and then a drying process was performed with a dryer having a temperature of 110 ° C. As a result, the basis weight is 40 g / m, in which the fibers are precisely three-dimensionally entangled.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0048]
[Table 1]
(Example 2)
As the fine fine fibers, polyester short fibers having the same single yarn fineness of 0.7 denier as in Example 1 were used. On the other hand, a polyester short fiber manufactured by Nippon Ester Co., Ltd. having a single yarn fineness of 6 denier, a fiber length of 51 mm, and a fiber cross section of a parallel hollow composite cross section was used as the thick fine fiber. The single yarn fineness ratio of the fine fine fiber and the thick fine fiber was 8.6. Other than that, the basis weight was 40 g / m in the same manner as in Example 1.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0050]
(Example 3)
As the fine fine fibers, polyester short fibers having the same single yarn fineness of 0.7 denier as in Example 1 were used. On the other hand, as the thick fine fibers, polyester short fibers made by Nippon Ester Co., Ltd. having a single yarn fineness of 10 denier, a fiber length of 51 mm, and a fiber cross section of a parallel hollow composite cross section were used. The single yarn fineness ratio of the fine fine staple fibers and the thick fine staple fibers was 18.6. Other than that, the basis weight was 40 g / m in the same manner as in Example 1.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0051]
(Example 4)
As the fine fine fiber, a polyester short fiber manufactured by Nippon Ester Co., Ltd. having a single yarn fineness of 1.3 denier, a fiber length of 38 mm, and a fiber cross section having a solid round cross section was used. On the other hand, polyester short fibers having a single yarn fineness of 6 deniers and a fiber length of 51 mm were used as thick fine fibers. The single yarn fineness ratio between the fine fine fiber and the thick fine fiber was 4.6. Other than that, the basis weight was 40 g / m in the same manner as in Example 1.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0052]
(Example 5)
As the fine fine fibers, polyester short fibers having the same single yarn fineness of 1.3 denier as in Example 4 were used. On the other hand, polyester short fibers having a single yarn fineness of 13 denier were used as thick fine fibers. The single yarn fineness ratio of the fine fine fiber and the thick fine fiber was 10.0. Otherwise, the basis weight was 40 g / m in the same manner as in Example 1.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0053]
(Example 6)
As the fine fine fibers, polyester short fibers having the same single yarn fineness of 1.3 denier as in Example 4 were used. On the other hand, polyester short fibers manufactured by Nippon Ester Co., Ltd. having a single yarn fineness of 20 denier, a fiber length of 76 mm, and a fiber cross section of a parallel hollow composite cross section were used as the thick fine fibers. The single yarn fineness ratio of the fine fine fiber and the thick fine fiber was 15.4. Otherwise, the basis weight was 40 g / m in the same manner as in Example 1.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0054]
(Example 7)
The basis weight is 40 g / m in the same manner as in Example 1 except that the blend ratio of the fine fine short fibers and the thick fine short fibers is set to (weight fine fine fibers) :( fine fine fine fibers) = 25: 75.2A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0055]
(Example 8)
40 g / m per unit area in the same manner as in Example 1 except that the blend ratio of the fine fine staple fibers and the thick fine staple fibers was changed to a weight ratio of (fine fine staple fibers) :( thick fine staple fibers) = 75: 25.2A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
Table 1 shows the production conditions and physical properties of the obtained nonwoven fabric.
[0056]
Example 9
As the fineness short fiber, a short fiber made of polyethylene and polyethylene terephthalate and having a sectional composite section having a shape as shown in FIG. 1 was used.
[0057]
The fineness short fibers were produced as follows. That is, high-melting polyethylene 1 having a melting point of 130 ° C. and a melt index value (measured by ASTM-D-1238 (E) method) of 25 g / 10 min, a melting point of 256 ° C., and phenol: tetrachloroethane = 1: 1 Using a
[0058]
Using the unbroken fine short fibers and the polyester short fibers having a fineness of 10 denier used in Example 3, the blending ratio was 50/50% by weight, and a non-woven web was obtained with a parallel card machine. . Next, the basis weight was 40 g / m, in which the fibers were densely three-dimensionally entangled under the same conditions as in Example 1 except that the drying temperature was 100 ° C.2 A short fiber nonwoven fabric was obtained. As a result of observing the obtained nonwoven fabric with a microscope, polyethylene 1 and
[0059]
Moreover, the single yarn fineness of polyethylene 1 and
[0060]
(Comparative Example 1)
As the fine fine fibers, polyester short fibers having the same single yarn fineness of 1.3 denier as in Example 4 were used. On the other hand, polyester short fibers having the same single yarn fineness of 3 denier as in Example 1 were used as the thick fine fibers. The single yarn fineness ratio of the fine fine fiber and the thick fine fiber was 2.3. The fine fine staple fibers and the thick fine staple fibers are mixed in a weight ratio of 50:50, and the basis weight is 40 g / m in the same manner as in Example 1.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0061]
(Comparative Example 2)
As the fine fine fibers, polyester short fibers having the same single yarn fineness of 0.7 denier as in Example 1 were used. On the other hand, polyester short fibers having a single yarn fineness of 30 denier were used as thick fine fibers. The single yarn fineness ratio of the fine fine fiber and the thick fine fiber was 42.9.
[0062]
The fine fine fiber and the short fine fiber are mixed at a weight ratio of 50:50, and under the same conditions as in Example 1, the basis weight is 40 g / m.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0063]
(Comparative Example 3)
A polyester short fiber having a single yarn fineness of 3 denier was used as the fine fine fiber short fiber, and a polyester short fiber having a single yarn fineness of 13 denier was used as the thick fine fiber short fiber. The single yarn fineness ratio of the fine fine fiber and the thick fine fiber was 4.3.
[0064]
The fine fine fiber and the short fine fiber are mixed at a weight ratio of 50:50, and under the same conditions as in Example 1, the basis weight is 40 g / m.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0065]
(Comparative Example 4)
40 g / m per unit area under the same conditions as in Example 1 except that a polyester short fiber having a fineness of 0.7 denier is the same as in Example 1.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
Table 1 shows the production conditions and physical properties of the obtained nonwoven fabric.
[0066]
(Comparative Example 5)
40 g / m per unit area under the same conditions as in Example 1 except that the polyester short fiber having a single yarn fineness of 13 denier was used.2 A short fiber nonwoven fabric was obtained. Table 1 shows the characteristics of the constituent fibers and the physical properties of the obtained nonwoven fabric.
[0067]
Since the nonwoven fabric obtained in Examples 1 and 2 is the short fiber nonwoven fabric of the present invention, it was excellent in nonwoven fabric strength and bulkiness as mechanical properties.
The nonwoven fabric obtained in Example 3 was more excellent in bulkiness because the single yarn fineness of the thick fine fibers was larger than that in Examples 1 and 2.
[0068]
The nonwoven fabrics obtained in Examples 4, 5, and 6 were more excellent in bulkiness because the single yarn fineness of the fine fineness short fibers and the thick fineness short fibers was larger than that of Example 1.
The nonwoven fabric obtained in Example 7 was more excellent in bulkiness because the blending ratio of thick fine fibers was larger than that in Example 1.
[0069]
The nonwoven fabric obtained in Example 8 was superior in the surface smoothness of the nonwoven fabric and in the strength of the nonwoven fabric because the blend ratio of the fine fineness short fibers was larger than that in Example 1.
[0070]
The nonwoven fabric obtained in Example 9 was more excellent in bulkiness since the single yarn fineness of the thick fine fibers was larger than that in Example 1. Further, in Example 9, unlike the other examples, the short fibers obtained by splitting the short fibers having the split composite cross section as the fineness short fibers were used, but as in the other examples. A short fiber nonwoven fabric excellent in strength and bulkiness of the nonwoven fabric was obtained.
[0071]
The nonwoven fabric obtained in Comparative Example 1 had a single yarn fineness ratio that was smaller than the lower limit of the range of the present invention.
The nonwoven fabric obtained in Comparative Example 2 was significantly inferior in strength of the nonwoven fabric although it was excellent in bulkiness because the single yarn fineness of the thick fine fibers was larger than the upper limit of the range of the present invention.
[0072]
The nonwoven fabric obtained in Comparative Example 3 had a single yarn fineness of the fine fineness short fibers that was larger than the upper limit of the range of the present invention, and thus was excellent in bulkiness but extremely inferior in nonwoven fabric strength.
[0073]
Since the nonwoven fabric obtained in Comparative Example 4 was composed only of short fine fibers, it was excellent in nonwoven strength but was not bulky.
Since the nonwoven fabric obtained in Comparative Example 5 was composed only of short fibers having a large fineness, the nonwoven fabric was extremely inferior in strength but excellent in bulkiness.
[0074]
【The invention's effect】
According to the present invention, the single yarn fineness of the fine fine fiber is 0.1 to 2 denier, the single fineness of the thick fine fiber is 3 to 25 denier, and the fine fine fiber and the thick fine fiber are The single yarn fineness ratio is (single yarn fineness of thick fine short fibers) / (single yarn fineness of fine fine short fibers) = 3-50, using fine fine short fibers and thick fine short fibers,Based on high pressure liquid flow treatmentThe constituent fibers are integrated by three-dimensional entanglement,Because the fine fine staple fibers are entangled with the thick fine staple fibers to connect the fine fine staple fibers together, and the fine fine staple fibers are also entangled with each other.Nonwoven fabric strong and bulkyExcellent and surface smoothnessAn excellent short fiber nonwoven fabric can be obtained.
[0075]
The short fiber nonwoven fabric of this invention consists of the said structure, and is used suitably for various uses.
For example, the short fiber nonwoven fabric of the present invention is excellent in wear resistance and durability because it is composed of thick fine fibers, and has a small fiber gap due to dense interlacing of fine fine fibers and thick fine fibers. Have a large portion of fiber voids due to entanglement. Therefore, when the short fiber nonwoven fabric of the present invention is used as a filter or wiper, it is possible to maintain the collection performance of dust and the like over a long period of time, and collect coarse particles and coarse dust at a portion where the fiber voids are large. In addition, since fine particles and fine dust can be collected at a small portion of the fiber gap, it is possible to separate and collect according to the object to be collected even though it is a single non-woven fabric. Furthermore, since the coefficient of friction is smaller than that of a short fiber nonwoven fabric composed only of short fine fibers, it has excellent strike-through properties and is suitably used as a household or commercial flooring wiper.
[0076]
Moreover, since it is excellent in bulkiness, heat retention, etc., it is also suitably used as a cushioning material such as a quilting pad, a flooring material or a wall material, and a sound absorbing material.
In addition, since the thick fine fibers are gently entangled while maintaining the crimped form, the nonwoven fabric has a moderate elasticity, and when used as a molding nonwoven fabric, the nonwoven fabric is not broken into a mold. Since the non-woven fabric form is maintained by the fine entanglement of the fine fibers along the fine lines, there is an effect of having excellent moldability.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a cross-sectional view of a fine fine fiber having a split composite cross section for constituting a nonwoven fabric according to an embodiment of the present invention.
[Explanation of symbols]
1 Polyethylene
2 Polyethylene terephthalate
Claims (4)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP8983897A JP3948781B2 (en) | 1997-04-09 | 1997-04-09 | Short fiber nonwoven fabric and method for producing the same |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP8983897A JP3948781B2 (en) | 1997-04-09 | 1997-04-09 | Short fiber nonwoven fabric and method for producing the same |
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| Publication Number | Publication Date |
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| JPH10280259A JPH10280259A (en) | 1998-10-20 |
| JP3948781B2 true JP3948781B2 (en) | 2007-07-25 |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| AU2009322091B2 (en) | 2008-12-04 | 2015-10-29 | Zephyros, Inc. | Nonwoven textile made from short fibers |
| DE102013111499A1 (en) * | 2013-10-18 | 2015-04-23 | Ascania Nonwoven Germany Gmbh | Bulky nonwoven composite and method of making the same |
| US9546439B2 (en) | 2014-05-15 | 2017-01-17 | Zephyros, Inc. | Process of making short fiber nonwoven molded articles |
| CN107407097B (en) | 2014-12-08 | 2020-11-13 | 泽菲罗斯公司 | Vertical lapping fiber floor |
| WO2016115138A1 (en) | 2015-01-12 | 2016-07-21 | Zephyros, Inc. | Acoustic floor underlay system |
| CN107206732B (en) | 2015-01-20 | 2021-02-26 | 泽菲罗斯公司 | Non-woven material with aluminized surface |
| EP3297821B1 (en) | 2015-05-20 | 2022-07-06 | Zephyros Inc. | Multi-impedance composite |
| JP7050281B2 (en) * | 2017-12-20 | 2022-04-08 | ユニチカ株式会社 | Laminated non-woven fabric |
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