EP0624676A1 - Non-tisse de fibres ultrafines et procede pour sa fabrication - Google Patents

Non-tisse de fibres ultrafines et procede pour sa fabrication Download PDF

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Publication number
EP0624676A1
EP0624676A1 EP93921107A EP93921107A EP0624676A1 EP 0624676 A1 EP0624676 A1 EP 0624676A1 EP 93921107 A EP93921107 A EP 93921107A EP 93921107 A EP93921107 A EP 93921107A EP 0624676 A1 EP0624676 A1 EP 0624676A1
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EP
European Patent Office
Prior art keywords
filaments
component
bicomponent conjugate
bicomponent
nonwoven fabric
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EP93921107A
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German (de)
English (en)
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EP0624676A4 (fr
EP0624676B1 (fr
Inventor
Shigemitsu Research & Development Center Murase
Eiichi Research & Development Center Kubo
Koichi Research & Development Center Nagaoka
Yoshiki Research & Development Center Miyahara
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Unitika Ltd
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Unitika Ltd
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments

Definitions

  • the present invention relates to a nonwoven fabric made of fine denier filaments suitable for a padding in clothing, a material for medical or sanitary use, etc., and to a production method thereof.
  • the nonwoven fabric is highly bulky, with high heat insulation and high tensile strength.
  • Nonwoven fabrics have been heretofore popularly employed in such uses as clothing materials, industrial materials, geotextile materials, construction materials, agricultural materials, horticultural materials, living materials, medical materials or sanitary materials.
  • a nonwoven fabric made of continuous filaments has advantages of high tensile strength and high productivity, as compared with nonwoven fabric made of staple fibers.
  • the production of the nonwoven fabric with high thermal insulation, while maintaining the above advantages may specifically require the filament denier as fine as possible.
  • nonwoven fafric made of fine denier filaments various method have been well known including, for example, a method in which bicomponent conjugate filaments of the both component incompatible each other are splitted by a needle punching, another method in which the said bicomponent conjugate filaments are subject to a treatment with a solvent thereby swelling and dissolving one component while separating another component therefrom, or a method in which bicomponent conjugate filaments are splitted by applying a water jet needling thereto.
  • the needle punching tends to be effective only when the weight (per square meter) of the nonwoven fabric is in the range of 400 to 800 g/m2. This is because if the number of filaments per unit area is small, sufficient entanglements are not achieved by the needle punching. Accordingly, the obtained nonwoven fabric tends to be high with its weight and, moreover, remarkably poor with its softness.
  • the Japanese Patent Publication (examined) No. 47585/1989 disclosed one of such methods.
  • sheath-core type bicomponent conjugate filaments are employed, and the water jet needling is applied to these filaments after making them webs, whereby a nonwoven fabric made of filaments which are finer than 0.5d and three-dimensionally entangled one another is obtained.
  • the Japanese Laid-Open Patent Publication (unexamined) No. 219653/1981 proposed a nonwoven fabric mainly composed of multi-filaments which are 0.3 to 9.0 denier.
  • the nonwoven fabric is characterized in that the multi-filaments are crossed over in random direction and entangled one another.
  • the multi-filament said above is composed of fine denier filaments which are finer than 0.5d and substantially continuous.
  • the nonwoven fabric made of very fine denier filaments exclusively composed of core components is obtained by crushing sheath components of the sheath-core type bicomponent conjugate filaments, the crushed sheath components cannot be utilized to be any filament for forming the nonwover fabric, and the crushed pieces of the sheath components may result in dust.
  • an object of the present invention is to provide a novel nonwoven fabric which has the superior bulkiness and the superior heat insulating, by properly employing bicomponent conjugate filaments which are splitable and heat sensitive adhesive, and by applying a heat to a web formed of the accumulated bicomponent conjugate filaments, using a heat embossing method, for example, thereby manifesting a heat sensitive adheasion to form many heat bonded areas with a certain distance kept one another where the bicomponent conjugate filaments are bonded to each other, and by splitting the bicomponent conjugate filament located in a non-heat bonded areas while applying a wrinkling treatment to the filaments without breaking or damaging the bonded areas and without making any substantial three-dimensional entaglement.
  • the present invention relates to a nonwoven fabric made of fine denier filaments which is composed of bicomponent conjugate filaments.
  • the bicomponent conjugate filament is bicomposed of a thermoplastic polymer component "A”, and a thermoplastic polymer component “B” insoluble in the component “A” and having a melting point higher than that of the component "A” by 30 to 180°C, and in which at least the component "A” is exposed on a surface of the bicomponent conjugate filament.
  • Heat bonded areas are formed by heat bonding the bicomponent conjugate filaments mutually to one another. The heat bonded areas are provided with a certain space between one heat bonded area and another by softening or melting only the component "A" of the bicomponent conjugate filaments.
  • Non heat bonded areas, without heat bonding the said conjugate filaments of the component "A” and “B", are also formed, being manifested by filaments "A”, exclusively composed of the component “A”, filaments “B”, exclusively composed of the component “B”, and non-splitted conjugate filaments coexisting therein.
  • the filaments "A”, the filaments "B” and the non-splitted bicomponent conjugate filaments are mixedly contained in the non heat bonded area without substantial three-dimensional entanglement thereamong.
  • the invention also provides a method for producing a nonwoven fabric made of fine denier filaments comprising the steps of: forming a web by accumulating bicomponent conjugate filaments, each of which is bicomposed of a thermoplastic polymer component "A” and a thermoplastic polymer component “B” insoluble in the component “A” and having a melting point higher than that of the component "A” by 30 to 180°C, and in which at least the component "A” is exposed on a surface of the bicomponent conjugate filament; applying a heat to predetermined areas on the web with a certain space in a direction of a thickness of the web, thereby softening or melting only the component "A", and obtaining a fleece in which the heat bonded areas formed by heat bonding the bicomponent conjugate filaments are formed with a certain space; and wrinkling the fleece to split said bicomponent conjugate filament existing in a non-heat bonded areas, thereby manifesting filaments "A” exclusively composed of the component "A” and filaments "B”
  • the bicomponent conjugate filament employed in the invention is hereinafter described.
  • the bicomponent conjugate filament is formed by bicomposing a thermoplastic polymer component "A” and a thermoplastic polymer component “B” which is insoluble in the component “A” and has a melting point higher than that of the component "A” by 30 to 180°C. At least the component “A” is exposed on the surface of the bicomponent conjugate filament.
  • a thermoplastic polymer is employed as the component "A” for the purpose of heat bonding the bicomponent conjugate filaments to one another. Therefore, at least one part of the component "A" must be exposed on the surface of the bicomponent conjugate filament.
  • any bicomponent conjugate filament cannot be bicombined with other bicomponent conjugate filament in spite of heat bonding.
  • the component "B” must have a melting point higher than that of the component "A” by 30 to 180°C, preferably by 40 to 160°C, and most preferably by 50 to 140°C. If the difference in the melting point between these two components is less than 30°C, when melting or softening the component "A", the component "B” becomes also easy to be softened or degraded. And then, a thermal degradation of a filament structure of the bicomponent conjugate filament may be brought about, which eventually results in a reduction of a mechanical strength of the obtained heat bonded areas.
  • the melting points of the components "A” and “B” according to the invention were measured by the following method. That is, each melting point is measured by differential calorimeter (Perkin-Elmer PSC-2C) at a heating rate of 20°C/min.
  • the component "A” must be a polymer insoluble in the polymeric component "B", for the purpose of reducing an affinity between the components "A” and “B” thereby making it easy to separate the component "A” and “B” from each other.
  • this splitting function is improved all the more when both components "A” and “B” are exposed on the surface of the bicomponent conjugate filaments.
  • polyamide/polyester polyolefin/polyester, polyolefin/polyamide or the like
  • polyamide/polyester polyolefin/polyester, polyolefin/polyamide or the like
  • Polyethyleneterephthalate, polybutylenetelephthalate, copolyesters mainly composed of them or the like can be employed as the polyester.
  • Nylon 6, nylon 46, nylon 66, nylon 610, copolyamides mainly composed of the nylons specified here or the like can be employed as the polyamides.
  • Polypropylene, high density polyethylene, linear low density polyethylene, ethylene-propylene copolymers or the like can be employed as the polyolefin.
  • lubricants, pigment, delustering agents, thermo-stabilizer, light resistant agents, UV absorber, antistatic agents, conductive agent, heat reserve agents, etc. can be added to the component "A" or component "B" when required.
  • any configuration for bicomposing the components "A” and “B” can be employed as far as the mentioned specific requirements are satisfied. More specifically, it is preferable to bicompose the component “A” and “B” in such a manner that cross-section of the bicomposed conjugate filament may be formed as illustrated in Fig. 1 to Fig. 4. It is necessary for the component “A” at least to be exposed on the surface of the bicomponent conjugate filament, and it is also preferable that both components “A” and “B” are exposed on the surface of the bicomponent conjugate filament. In the drawings, portions indicated by oblique line parts are the component "B", and portions indicated by dotted parts are the component "A”. In Fig.
  • the blank center part indicated by neither oblique line part nor dotted part can be either hollow (hollow filament) or formed of any polymer component other than the components "A" and "B".
  • the bicomponent conjugate filaments illustrated in the drawings are almost circular and point symmetric in cross-section. It is, however, not always necessary to limit to this configuration, but it is also preferable to be of non-circular and a asymmetric in cross-section as a matter of course.
  • the bonding strength is reduced among the bicomponent conjugate filaments heat bonded, and it becomes difficult to give a sufficient tensile strength to the obtained nonwoven fabric.
  • the component "A” is more than 80 parts by weight, a heat bonding among the bicomponent conjugate filaments becomes excessively so strong that large openings are formed in the heat bonded areas due to the aggregation of the said bonded conjugate filaments, which eventually results in a reduction of the tensile strength of the obtained nonwoven fabric.
  • a fineness of the bicomponent conjugate filament employed in the invention can be also determined at discretion of a person skilled in the art, but preferably may be in the range of 2 to 12 denier (depending upon a specific gravity of a component polymer). If less than 2 deniers, the obtained bicomponent conjugate filaments are excessively fine, and it becomes difficult to produce them by spinning. On the contrary, if more than 12 denier, the bicomponent conjugate filaments are excessively thick, and it becomes difficult to obtain a web of a good appearance at a low weight.
  • a web is formed by employing the bicomponent conjugate filaments described above and accumulating them. It is preferable that the production of the bicomponent conjugate filaments and formation of the web are performed in the following manner.
  • the thermoplastic polymer component "A” such as the mentioned polyolefin is prepared.
  • the thermo-plastic polymer component "B” insoluble in the component "A” and having a melting point higher than that of the component A by 30 to 180°C is prepared.
  • the prepared two components "A” and “B” are then introduced in a melt spinning apparatus equipped with a bicomponent spinneret, and thus the bicomponent conjugate filaments are obtained by the conventionally known bicomponent melt spinning.
  • the spinning temperature is lower than the mentioned temperature range, it becomes difficult to make the spinning speed high and to obtain the bicomponent conjugate filaments of fine denier.
  • the spinning temperature is higher than the mentioned temperature range, a fluidity of the components "A" and "B” is increased, and there is a possibility of frequently occurring filament breaking at the time of melt spinning due to lower melt viscosity.
  • occurring filament breaking the broken part is transformed into a polymer drop, and such a polymer drop is mixedly included in the obtained nonwoven fabric, resulting in a deterioration of the nonwoven fabric quality.
  • the melt-spinned bicomponent conjugate filaments are then quenched and introduced in an air sucker.
  • the air sucker is also usually called air jet, which performs spinning and drawing of the filaments by a suction and discharge of air.
  • the bicomponent conjugate filaments introduced in the air sucker is discharged from an exit of the air sucker while being drawn by the air.
  • the bicomponent conjugate filament bundles are opened by means of a fiber opening apparatus provided at the exit of the air sucker.
  • a conventionally known method such as corona discharge or frictional electrification can be employed as the said opening method.
  • the opened bicomponent conjugate filaments are then accumulated on a moving conveyor of a wire gauge, etc. to be formed into a web.
  • a heat is applied to the said predetermined areas of the web in the direction of the thickness. Then only the component "A" of the bicomponent conjugate filaments in the predetermined areas is softened and molten, whereby the bicomponent conjugate filaments are heat bonded to form the heat bonded ares.
  • the predetermined (heat bonded) areas are provided with a certain space between one area and another, for example, in the form of dots or lattices in the web. In the predetermined areas, the heat is applied thereto in the direction of the web thickness so as to be of almost the same temperature throughout the said predetermined areas.
  • the heat is not applied in the direction of the thickness but applied only to the surface or back side of the web, there arises a problem that the component "A" of the bicomponent conjugate filaments is not sufficiently softened or molten in the middle of the thickness of the web, and the bicomponent conjugate filaments are not sufficiently heat bonded to one another, and as a result the tensile strength of the obtained nonwoven fabric is not improved.
  • a desirable heat application method it is, for example, possible to employ an embossing apparatus comprising an engraved roller and a flat roller or another embossing apparatus comprising a pair of engraved rollers, and to press the web with convex parts of the heated engraved rollers.
  • the convex parts have been heated to a temperature not higher than the melting point of the component "A". If the convex parts have been heated to be higher than the melting point of the component "A", the component "A" is molten even in the other areas than the areas on the web pressed by the convex parts, in such cases the heat bonded areas becomes larger than the predetermined percentage, resulting in poor softness of the obtained nonwoven fafric.
  • any pattern can be employed as the pattern of the top face of the convex part, i,e., the top face of the convex part of the engraved roller can be circular, ellipsoidal, diamond-shaped, triangular, T-shaped, #-shaped or lattice shaped.
  • the heat bonded areas can be formed with the use of an ultra-sonic bonding apparatus.
  • the ultra-sonic bonding apparatus radiates an ultra-sonic wave to the predetermined areas of the web, whereby the component "A" is molten by a frictional heat generated among the bicomponent conjugate filaments in the areas.
  • the heat bonded areas can be formed in the web at any desired percentage, but in the invention, it is preferable that the heat bonded areas are formed so as to occupy 5 to 50% of the entire area of the obtained nonwoven fabric. If the heat bonded areas are less than 5% of the entire area of the obtained nonwoven fabric, the tensile strength of the obtained nonwoven fabric tends to be decreased. On the contrary, if the heat bonded areas are more than 50%, the heat bonded areas in which the bicomponent conjugate filaments are heat bonded is increased, and the softeness of the obtained nonwoven fabric tends to be poor.
  • a fleece in which the bicomponent conjugate filaments are heat bonded to one another in the predetermined areas is obtained.
  • the fleece is then subject to wrinkling.
  • a wrinkling method for example, there are several applicable methods such as a bending-compression method in which, at the time of introducing the fleece between the rollers, an input speed is made higher than an output speed so as to bend the fleece, and high pressure liquid current application method in which a high pressure liquid current is applied to the fleece, etc. Any other method can be applied as far as a wrinkling action for splitting the bicomponent conjugate filaments may be sufficiently applied to the fleece.
  • the mentioned splitting treatment by wrinkling has the following advantages as compared with the treatment by the conventionally known needle punching or water jet needling. More specifically, in the treatment by the needle punching or the water jet needling, it is certain that the bicomponent conjugate filaments are successfully splitted in the portion where punching needle or water jet needle has passed through, but it is difficult that the bicomponent conjugate filaments may be splitted in the portion where the punching needle or the water jet needle has not passed through, resulting in a low splitting percentage of the bicomponent cojugate filaments. On the other hand, because the wrinkling employed in the invention is applied evenly to the entire bicomponent conjugate filaments, the splitting can be preferably achieved at a high percentage.
  • the bicomponent conjugate filaments are successfully splitted also in the areas other than the heat bonded areas, i.e., non-heat bonded areas, whereby the filaments "A" exclusively composed of the component "A", and the filaments "B” exclusively composed of the components "B” are produced.
  • a splitting extent, i.e., a splitting percentage of the bicomponent conjugate filaments in the non-heat bonded areas is preferably not less than 70%, and more preferably not less than 95%. The splitting percentage is determined depending upon how much length is to be splitted longitudinally along the full length of the bicomponent conjugate filaments existing in the non-heat bonded area.
  • the split percentage is 70%. It is to be noted that, by producing the filaments "A" and “B” both of a finer denier than that of the bicomponent conjugate filaments, the softness of the non-heat bonded areas is improved, and the bulkiness of the non-heat bonded areas is increased thereby improving the heat insulating property. In the meantime, the bicomponent conjugate filaments existing in the heat bonded areas are combined one another by the heat bonding of the component "A", therefore, are almost unsplitted.
  • the nonwoven fabric obtained in the mentioned manner is further described more specifically hereinafter with reference to Fig. 6 and Fig. 7.
  • the nonwoven fabric 6 made of fine denier filaments is formed of the heat bonded areas 11 and the non-heat bonded areas 12.
  • the bicomponent conjugate filaments are mutually combined by heat bonding the component "A”
  • the filaments "A" and filaments "B” both produced by splitting the bicomponent conjugate filaments are accumulated to be bulky without a substantial filament combination and entanglement.
  • the filaments "A” exclusively composed of the component "A" which are produced by splitting the bicomponent conjugate filaments are preferably in the range of 0.05 to 2.0 denier.
  • the filaments "B” exclusively composed of the component “B” are preferably in the range of 0.02 to 0.8 denier.
  • the filaments "A” and “B” may have the same denier, but usually the filament “A” has a relatively large denier (i.e., 1.5 to 3 times as large as a denier of the filaments "B”). Because it is sometimes the case to use the bicomponent conjugate filaments, in which the component "B” is separated into a large number of parts and arranged on the surface of the bicomponent conjugate filaments, the component "A”, is located in the center of the bicomponent conjugate filaments without such a separation, as illustrated in Fig. 1 or Fig. 4.
  • the length of the bicomponent conjugate filaments employed in the invention is infinitely long, and accordingly, the bicomponent conjugate filaments extend over the heat bonded areas 11 and non-heat bonded areas 12. In the heat bonded areas 11, the bicomponent conjugate filaments are combined one another by the heat bonding of the component "A”, and these bicomponent conjugate filaments are splitted in the non-heat bonded areas 12.
  • the nonwoven fabric 6 made of fine denier filaments obtained by the method in accordance with the invention is composed of a large number of accumulated bicomponent conjugate filaments, and in each of the bicomponent conjugate filaments, the portions existing in the heat bonded areas 11 are mutually combined one another, while the portions existing in the non-heat bonded areas 12 are splitted to form the filaments "A" and "B", in the machine direction of the conjugate filaments.
  • the portion of the filaments forming the non-heat bonded areas 12 and those forming the heat bonded areas 11 are continuously linked each other, thereby a high tensile strength being achieved sufficiently.
  • the basis weight (per square meter) of the nonwoven fabric made of fine denier filaments obtained by the method in accordance with the invention can be determined at discretion of the person skilled in the art, but it is usually in the weight of 10 to 250g/m2.
  • the nonwoven fabric made of fine denier filaments of the lower weights is preferably fit for various uses including bedclothes such as a bed sheet or a pillow case, absorbents for hygienic goods such as a sanitary napkin or a diaper, or oil absorbents for domestic and industrial uses.
  • the nonwoven fabric made of fine denier filaments of the higher weights is preferably fit for various uses including filter materials, waddings for sleeping bag or other bedclothes, dummy weight fillings, ground fabrics for carpet or artificial leathers, fertilizer abosrbents for gardening or seed beds, heat insulating materials for buildings or walls thereof.
  • the nonwoven fabric made of fine denier filaments obtained as described above and the production method thereof in according to the present invetnion have the following techinical advantages.
  • Specified bicomponent conjugate filaments employed in the invention perform functions bothly as heat sensitive adhesive filaments and as splitting type filaments. Accordingly, taking advantage of such characteristic functions, in the predetermined areas of the web formed by accumulating the bicomponent conjugate filaments, the function of the heat sensitive adhesiveness is caused to be manifested for heat bonding the bicomponent conjugate filaments to one another, while in the areas other than the heat bonded areas of the web, the splitting function is caused to be manifested for producing the nonwoven fabric made of fine denier filaments from the bicomponent conjugate filaments.
  • the obtained nonwoven fabric has an unique advantage in the aspects of the bulkiness, the heat retaining property and the softness.
  • the wrinkling is employed as a splitting process of the bicomponent conjugate filaments. Accordingly, the splitting percentage of the bicomponent conjugate filaments becomes much higher as compared with that by the conventional needle punching or the conventional water jet needling. As a result, a technical advantage is performed such that splitting takes place also in the non-heat bonded areas, whereby the obtained nonwoven fabric is improved in the aspects of the bulkiness, the heat insulating property and the softness.
  • the bicomponent conjugate filaments are splitted by the said wrinkling action, a further technical advantage is performed such that there is no problem that the foreign material having a strong impact force runs through the fleece as is often the case in the conventional needle punching or the conventional water jet needling.
  • the heat bonded areas are almost free from any breakdown or damage, and the obtained nonwoven fabric is prevented from the reduction of the tensile strength.
  • the splitted filaments are easy to be three-dimensionally entangled as mentioned above.
  • the splitted filaments are hardly three-dimensionally entangled.
  • a still further technical advantage is performed such that the splitted filaments are prevented from the reduction of the bulkiness without three-dimensional entanglement in the non-heat bonded areas.
  • the bicomponent conjugate filaments existing in these areas are almost perfectly heat bonded to one another. It is also to be noted that the filaments existing in both heat bonded areas and non-heat bonded areas derive from the same bicomponent conjugate filaments, though their mechanical and thermal conditions are different, and the bicomponent conjugate filaments extend over and run through both heat bonded areas and non-heat bonded areas and, moreover, the non-heat bonded areas are formed of fine denier filaments.
  • the bicomponent conjugate filaments are necessarily heat bonded to one another in the heat bonded areas, and these heat bonded areas are connected one another through fine denier filaments in the non-heat bonded areas.
  • a tensile force is applied to such a nonwoven fabric made of fine denier filaments, a yet further advantage is performed such that both heat bonded areas and non-heat bonded areas are hardly broken, and exhibit the high tensile strength.
  • thermoplastic polymer component "A” A high density polyethylene, of which melting point was 130°C and the melt index value (measured in accordance with the method prescribed in ASTM D1238 (E)) was 20g/10min, was prepared as a thermoplastic polymer component "A".
  • the bicomponent melt spinning was performed in such a manner that the polymer output of each orifice was 1.20g/min, the component "A" output of each orifice was 0.60g/min, and the component "B” output of each orifice was 0.60g/min.
  • the spinning temperature was set to 230°C for the component A and to 285°C for the component B.
  • the bicomponent conjugate filaments were drawn at a speed of 4000m/min by six suckers per one spinning position each disposed 120cm below the spinneret.
  • Each of the bicomponent conjugate filaments obtained in this manner having a cross-sectional view as illustrated in Fig. 1 was 2.70 denier in fineness.
  • the drawn bicomponent conjugate filament bundles were subject to opening by a corona discharge and accumulated on a moving conveyor net, thereby a web being formed. The web was introduced between an engraved roller and a flat roller both heated to 120°C.
  • This appparatus was Microceper II produced by Micrex Co., and the conditions of the wrinkling were set to be as follows: Working speed: 10m/min, Nip pressure of feed rollers 1, 2: 6kg/cm2; Pressure of upper retarder 3: 3kg/cm2; Temperature of feed rollers 1, 2: 50°C; Pressure of lower retarder 4: 5kg/cm2; Distance between a tangent at the contact point between feed rollers 1, 2 and upper retarder 3: 5mm; and Distance between a tangent at the contact point between feed rollers 1, 2 and lower retarder 4: 10mm.
  • the reference numeral 5 indicates the fleece and the numeral 6 indicates the obtained nonwoven fabric made of fine denier filaments.
  • thermoplastic polymer component A A nylon 6, of which the melting point was 130°C and the relative viscosity measured with 96% concentration solution of sulfuric acid at 25°C was 2.57, was prepared as a thermoplastic polymer component A. Further, a polyethyleneterephthalate same as the one employed in Example 1 was prepared as a thermoplastic polymer component B. Then, a bicomponent melt spinning was performed employing these components A and B. In this step, the bicomponent melt spinning was performed in the same manner as the foregoing Example 1, except that orifices by which 16 radial segments and center hollow segment were formed were employed as spinning orifices so as to obtain the bicomponent conjugate filaments having a sectional view illustrated in Fig. 2, and spinning temperature of the component A was set to 270°C.
  • the bicomponent conjugate filaments were drawn by air suckers in the same manner as the foregoing Example 1, whereby the bicomponent conjugate filaments having a cross-section as illustrated in Fig. 2 were obtained, and of which the denier was 2.7.
  • a web was formed in the same manner as the foregoing Example 1, and a fleece was obtained in the same manner as the foregoing Example 1 except that the temperatures of the engraved roller and flat roller were set to 210°C.
  • the wrinkling was then applied to this fleece in the same manner as the foregoing Example 1, and thus a nonwoven fabric made of fine denier filaments was obtained.
  • the wrinkling is applied to the fleece obtained in the foregoing Example 2 by means of a "Loco" type jet dyeing machine (produced by Hokuriku Kakoki). Simultaneously with such wrinkling, dyeing was applied to the componenet of nylon 6 included in the fleece and to the fine filaments of nylon 6 produced by the wrinkling.
  • aqueous solution 2000 liter containing of Blue FFB (produced by Sumitomo Chemical Company Ltd.) of 0.2% o.w.f. used as an acid dye, Migregal WA-10 (produced by Senka Co.,) of 0.5g/l used as a leveling agent, and an acetic acid disssolved so as to be pH 5 was employed.
  • Conditions of applying a liquid current to the fleece were established as follows: Liquid temperature: 100°C; Conveying speed of the fleece: 100m/min; Nozzle pressure: 3kg/cm2; and Application time: 1 hour.
  • a polyethyleneterephthalate and a polyethylene both same as the ones employed in the foregoing Example 1 were prepared.
  • Orifices in which 48 radial segments (24 segment each) and a center hollow segment were formed, were employed as spinning orifices so as to obtain the bicomponent conjugate filaments having a cross-section as shown in Fig. 2.
  • the output ratio of polyethyleneterephthalate/polyethylene from the orifices was set to be 1.5/1.
  • the bicomponent melt spinning was performed in the same manner as the foregoing Example 1 except that the spinning temperature of the component A was set to 270°C.
  • the bicomponent conjugate filaments were then drawn by air suckers in the same manner as the foregoing Example 1, whereby the bicomponent conjugate filaments having a cross-section as illustrated in Fig. 2, of which denier was 2.0 were obtained. Subsequently, a web was formed in the same manner as the foregoing Example 1, and a fleece was obtained in the same manner as the foregoing Example 1 except that the belt conveyor speed was changed. The wrinkling was then applied to this fleece in the same manner as the foregoing Example 1, and a nonwoven fabric made of fine denier filaments was obtained.

Abstract

Est décrit un non-tissé (6) de fibres ultrafines présentant d'excellentes caractéristiques de gonflant, de conservation de la chaleur et de résistance à la traction. Un constituant polymère thermoplastique A est préparé. Est également préparé un constituant polymère thermoplastique B non compatible avec le constituant A et présentant un point de fusion supérieur de 30°-180 °C à celui du constituant A. Une bande de fibres est formée par accumulation de fibres composites longues obtenues par un procédé de filage à chaud biconstituant, utilisant les constituants A, B, au moins le constituant A étant exposé sur les surfaces extérieures des fibres. Le constituant A uniquement est ensuite ramolli ou fondu par application de chaleur sur des régions prédéterminées de la bande de fibres dans le sens de son épaisseur, de sorte que les fibres composites longues sont réunies par la fusion. On obtient une nappe de fibres (5) ayant des régions prédéterminées espacées en pointillé ou en réseau. Cette nappe de fibres (5) est soumise à une étape de frottement. Les fibres composites longues se trouvant dans la région non fusionnée (12) sont divisées de sorte que la vitesse de division des fibres atteigne un niveau prédéterminé, afin de donner des fibres A composées du constituant A seul et des fibres B composés du constituant B seul.
EP93921107A 1992-10-05 1993-10-04 Non-tisse de fibres ultrafines et procede pour sa fabrication Expired - Lifetime EP0624676B1 (fr)

Applications Claiming Priority (3)

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JP29208792 1992-10-05
JP292087/92 1992-10-05
PCT/JP1993/001417 WO1994008083A1 (fr) 1992-10-05 1993-10-04 Non-tisse de fibres ultrafines et procede pour sa fabrication

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WO2001007698A1 (fr) * 1999-07-26 2001-02-01 Firma Carl Freudenberg Nappe de non-tisse pour la fabrication de vetement de protection pour salle blanche
DE19947869A1 (de) * 1999-10-05 2001-05-03 Freudenberg Carl Fa Synthetisches Leder
DE19962357A1 (de) * 1999-12-23 2001-07-05 Freudenberg Carl Fa Schlafbekleidung
DE19962360A1 (de) * 1999-12-23 2001-07-05 Freudenberg Carl Fa Arbeitsschutzbekleidung
WO2001048294A1 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Habillement hygienique
WO2001048292A1 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Linge hygienique
WO2001048278A2 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Vetement de sport
WO2001048295A1 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Thermomateriau non tisse
EP1118305A2 (fr) * 2000-01-22 2001-07-25 Firma Carl Freudenberg Serviette de nettoyage
WO2001064991A2 (fr) * 2000-02-28 2001-09-07 Carl Freudenberg Kg Materiau d'isolation phonique
DE10009283A1 (de) * 2000-02-28 2001-09-13 Freudenberg Carl Fa Airbagschutzhülle
DE10011053A1 (de) * 2000-03-07 2001-10-11 Freudenberg Carl Fa Textiles Lichtschutzmaterial
EP1150181A2 (fr) * 2000-04-26 2001-10-31 Japan Vilene Company, Ltd. Feuille de nettoyage pour un membre de fixage par fusion, dispositif d'alimentation de feuilles de nettoyage et appareil de nettoyage
DE10139227A1 (de) * 2001-08-09 2003-03-06 Freudenberg Carl Kg Airbagschutzhülle
US6739023B2 (en) 2002-07-18 2004-05-25 Kimberly Clark Worldwide, Inc. Method of forming a nonwoven composite fabric and fabric produced thereof
US7732357B2 (en) 2000-09-15 2010-06-08 Ahlstrom Nonwovens Llc Disposable nonwoven wiping fabric and method of production
WO2020170115A1 (fr) * 2019-02-21 2020-08-27 3M Innovative Properties Company Filet

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US6495255B2 (en) * 2000-06-26 2002-12-17 Chisso Corporation Polyolefin splittable conjugate fiber and a fiber structure using the same
DE10117970C1 (de) * 2001-01-19 2002-10-24 Freudenberg Carl Kg Verfahren zur Herstellung von Monokomponenten-Mikrofilamenten und Gewinnung eines Vlieses, Gewebes oder Gewirkes aus den Mikrofilamenten
JP4211496B2 (ja) * 2003-05-30 2009-01-21 東レ株式会社 吸音材構成部材および吸音材
US7645353B2 (en) 2003-12-23 2010-01-12 Kimberly-Clark Worldwide, Inc. Ultrasonically laminated multi-ply fabrics
DE102012002954B4 (de) * 2012-02-16 2015-07-02 Carl Freudenberg Kg Verwendung eines Mikrofilament-Vliesstoffs als textiles UV-Lichtschutzmaterial
DE102012222886B4 (de) * 2012-12-12 2014-11-27 Jöst Gmbh Genopptes Schleif- und Reinigungsvlies sowie Herstellung und Verwendung desselben

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DE19934442A1 (de) * 1999-07-26 2001-02-08 Freudenberg Carl Fa Vliesstoff zur Herstellung von Reinraum-Schutzbekleidung
DE19934442C2 (de) * 1999-07-26 2001-09-20 Freudenberg Carl Fa Verfahren zur Herstellung eines Vliesstoffs und Vliesstoff zur Herstellung von Reinraum-Schutzbekleidung
WO2001007698A1 (fr) * 1999-07-26 2001-02-01 Firma Carl Freudenberg Nappe de non-tisse pour la fabrication de vetement de protection pour salle blanche
US6815382B1 (en) 1999-07-26 2004-11-09 Carl Freudenberg Kg Bonded-fiber fabric for producing clean-room protective clothing
US6838043B1 (en) 1999-10-05 2005-01-04 Carl Freudenberg Kg Method for the production of a synthetic leather
DE19947869A1 (de) * 1999-10-05 2001-05-03 Freudenberg Carl Fa Synthetisches Leder
WO2001048295A1 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Thermomateriau non tisse
WO2001048278A2 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Vetement de sport
WO2001048278A3 (fr) * 1999-12-23 2001-12-27 Freudenberg Carl Fa Vetement de sport
DE19962355A1 (de) * 1999-12-23 2001-07-05 Freudenberg Carl Fa Sanitärbekleidung
WO2001048293A1 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Habillement de couchage
DE19962356A1 (de) * 1999-12-23 2001-07-05 Freudenberg Carl Fa Sanitärwäsche
DE19962361A1 (de) * 1999-12-23 2001-07-12 Freudenberg Carl Fa Sportbekleidung
DE19962360B4 (de) * 1999-12-23 2005-06-30 Carl Freudenberg Kg Arbeitsschutzbekleidung
WO2001048292A1 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Linge hygienique
WO2001048294A1 (fr) * 1999-12-23 2001-07-05 Carl Freudenberg Kg Habillement hygienique
DE19962360A1 (de) * 1999-12-23 2001-07-05 Freudenberg Carl Fa Arbeitsschutzbekleidung
DE19962357A1 (de) * 1999-12-23 2001-07-05 Freudenberg Carl Fa Schlafbekleidung
EP1118305A3 (fr) * 2000-01-22 2002-09-25 Carl Freudenberg KG Serviette de nettoyage
EP1118305A2 (fr) * 2000-01-22 2001-07-25 Firma Carl Freudenberg Serviette de nettoyage
DE10002778B4 (de) * 2000-01-22 2012-05-24 Robert Groten Verwendung eines Mikrofilament-Vliesstoffes als Reinigungstuch
DE10002778A1 (de) * 2000-01-22 2001-08-09 Freudenberg Carl Fa Reinigungstuch
WO2001064991A3 (fr) * 2000-02-28 2001-12-13 Freudenberg Carl Materiau d'isolation phonique
DE10009283C2 (de) * 2000-02-28 2002-02-21 Freudenberg Carl Kg Airbagschutzhülle
DE10009283A1 (de) * 2000-02-28 2001-09-13 Freudenberg Carl Fa Airbagschutzhülle
WO2001064991A2 (fr) * 2000-02-28 2001-09-07 Carl Freudenberg Kg Materiau d'isolation phonique
DE10011053A1 (de) * 2000-03-07 2001-10-11 Freudenberg Carl Fa Textiles Lichtschutzmaterial
DE10011053C2 (de) * 2000-03-07 2002-06-20 Freudenberg Carl Kg Textiles Lichtschutzmaterial
EP1150181A3 (fr) * 2000-04-26 2003-04-16 Japan Vilene Company, Ltd. Feuille de nettoyage pour un membre de fixage par fusion, dispositif d'alimentation de feuilles de nettoyage et appareil de nettoyage
EP1150181A2 (fr) * 2000-04-26 2001-10-31 Japan Vilene Company, Ltd. Feuille de nettoyage pour un membre de fixage par fusion, dispositif d'alimentation de feuilles de nettoyage et appareil de nettoyage
US7732357B2 (en) 2000-09-15 2010-06-08 Ahlstrom Nonwovens Llc Disposable nonwoven wiping fabric and method of production
DE10139227A1 (de) * 2001-08-09 2003-03-06 Freudenberg Carl Kg Airbagschutzhülle
US6739023B2 (en) 2002-07-18 2004-05-25 Kimberly Clark Worldwide, Inc. Method of forming a nonwoven composite fabric and fabric produced thereof
WO2020170115A1 (fr) * 2019-02-21 2020-08-27 3M Innovative Properties Company Filet
CN113474149A (zh) * 2019-02-21 2021-10-01 3M创新有限公司 结网

Also Published As

Publication number Publication date
KR100223388B1 (ko) 1999-10-15
KR940009409A (ko) 1994-05-20
DE69316337T2 (de) 1998-04-30
EP0624676A4 (fr) 1995-02-01
TW246699B (fr) 1995-05-01
WO1994008083A1 (fr) 1994-04-14
DE69316337D1 (de) 1998-02-19
EP0624676B1 (fr) 1998-01-14

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