EP2261410B1 - Vliesstoff aus polymilchsäurefilament und dessen herstellungsverfahren - Google Patents

Vliesstoff aus polymilchsäurefilament und dessen herstellungsverfahren Download PDF

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Publication number
EP2261410B1
EP2261410B1 EP20090167764 EP09167764A EP2261410B1 EP 2261410 B1 EP2261410 B1 EP 2261410B1 EP 20090167764 EP20090167764 EP 20090167764 EP 09167764 A EP09167764 A EP 09167764A EP 2261410 B1 EP2261410 B1 EP 2261410B1
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Prior art keywords
polymer
aliphatic polyester
nonwoven fabric
polyester polymer
polylactic acid
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EP20090167764
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English (en)
French (fr)
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EP2261410A1 (de
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Atsushi Matsunaga
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Unitika Ltd
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Unitika Ltd
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Priority claimed from JP2009129740A external-priority patent/JP5355225B2/ja
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Classifications

    • 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
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters

Definitions

  • the present invention relates to a nonwoven fabric and a production method thereof.
  • nonwoven fabrics having functionalities is a nonwoven fabric made of a self-adhesive fiber.
  • the nonwoven fabric made of a self-adhesive fiber is a fabric in which the fibers bond to each other to be integrated through melting of portions of the fibers by heating and which has a heat-sealing property.
  • nonwoven fabrics made of self-boding fibers using polylactic acid polymers are nonwoven fabrics made of sheath-core type fibers in each of which polylactic acid is disposed in the core portion thereof and a copolymer of L-lactic acid and D-lactic acid (D,L-lactic acid copolymer) is disposed in the sheath portion thereof and thus the sheath portion has a melting point lower than that of the core portion (Japanese Patent Laid-Open Nos. 07-310236 and 07-133511 ).
  • a composite fiber in which the melting point difference between the core portion and the sheath portion is as large as possible. Accordingly, it is conceived that a copolymer having a lower melting point (a copolymer having a melting point of about 120°C) is preferably selected as the copolymer for the sheath portion.
  • the copolymers having a melting point of about 120°C are low in crystallinity. Consequently, when nonwoven fabrics made of such sheath-core type fiber are applied for heat-sealing, troubles such as shrinkage in a thermal bonding step or fusion bonding to a hot roller tend to occur. Additionally, nonwoven fabrics obtained from such sheath-core type fiber are poor in heat resistance.
  • a method for solving such a problem is a technique which, when a low melting point polymer other than polylactic acid is used for the sheath portion, controls the crystallization rate of the polymer by a crosslinking reaction using an organic peroxide and performs cooling by a short cooling process (Japanese Patent Laid-Open No. 2007-084988 ).
  • Japanese Patent Laid-Open No. 2007-119928 discloses a composite fiber including a first biodegradable component and a second biodegradable component, and further describes a biodegradable composite fiber characterized in that the semi-crystallization time of the second component at 85°C is longer than the semi-crystallization time of the first component at 85°C, and a structure and a water absorption article using the biodegradable composite fiber.
  • the composite fiber described in this document Japanese Patent Laid-Open No. 2007-119928 , can be sufficiently satisfactorily applied when the length of the cooling zone in the spinning step can be sufficiently ensured.
  • the spunbond method having a short cooling zone when a resin having a longer semi-crystallization time is applied for the polymer for the sheath portion, sticking of filaments is caused.
  • a problem of the present invention is to provide a biodegradable nonwoven fabric that is satisfactory in the spinability and the spreading-open property of the constituent continuous filaments and is capable of being produced by the spunbond method and to provide a production method of the nonwoven fabric.
  • another problem of the present invention is to provide a biodegradable nonwoven fabric that is excellent in mechanical properties, has at the same time the heat-sealing property and is particularly excellent in flexibility and to provide a production method thereof.
  • the present inventors made an investigation to obtain, by the spunbond method, a nonwoven fabric even with a polymer having a low melting point and a low glass transition temperature. Consequently, it has been revealed that by selecting a specific polymer as an aliphatic polyester polymer which forms at least a portion of the filament surface such as the sheath component, and by further adding an amide wax to this polymer, the crystallization rate can be increased without adding an organic peroxide for crosslinking reaction, and sufficient cooling is performed even in the cooling step based on the spunbond method so as to cause no sticking.
  • the present invention has been perfected on the basis of the above-described findings.
  • the means for solving the above-described problems are as follows.
  • the aliphatic polyester polymer forming at least a portion of the filament surface, contains 0.1 to 1% by mass of an amide wax, and consequently the friction between the filaments at the time of spreading-open can be diminished.
  • a web satisfactory in spreading-open property can be produced, and hence a nonwoven fabric satisfactory in uniformity can be obtained.
  • the aliphatic polyester polymer used as the aliphatic polyester polymer is a specific aliphatic polyester polymer which has a crystallization rate index of 3 to 10 minutes and a melt viscosity gradient of 20 g/10 min or less obtained as the difference between a melt flow rate at 230°C and a melt flow rate at 210°C, both of the melt flow rates being measured according to the method described in ASTM-D-1238(E), and hence the crystallization rate of the aliphatic polyester polymer can be increased.
  • the aliphatic polyester polymer can be satisfactorily cooled and crystallized without developing therein such elasticity at the time of melting as developed by the crosslinking reaction.
  • the occurrence of the sticking in the spreading-open step can be effectively suppressed.
  • the nonwoven fabric made of the composite filaments including the polylactic acid polymer and the aliphatic polyester polymer which includes, as the constituent components thereof, 1,4-butanediol and succinic acid and has a melting point lower, by 50°C or more, than the melting point of the polylactic acid polymer. Consequently, there can be obtained a nonwoven fabric excellent in the stability at the time of heat processing and in the heat-sealing property.
  • the nonwoven fabric of the present invention is constituted with composite continuous filaments that includes a polylactic acid polymer, as a filament-forming component, having a melting point of 160°C or higher and an aliphatic polyester polymer, as a thermobonding component, having a melting point lower than the melting point of the polylactic acid polymer.
  • used as the polylactic acid polymer is a polymer having a melting point of 160°C or higher or a polymer blend composed of polymers each having a melting point of 160°C or higher.
  • the polylactic acid polymer has a high crystallinity owing to the melting point thereof being 160°C or higher, and thus the shrinkage at the time of heat treatment processing is unlikely to occur and the heat treatment processing can be performed stably.
  • the melting point of poly-L-lactic acid or poly-D-lactic acid that is a homopolymer of lactic acid is approximately 180°C.
  • the copolymerization ratio between the monomer components is determined in such a way that the melting point of the copolymer is 160°C or higher.
  • the melting point of the copolymer is lower than 160°C to preclude the attainment of the object of the present invention. More preferably, the melting point is 165°C or higher.
  • various additives such as a delustering agent, a pigment and a crystal nucleating agent may be added within the ranges that do not impair the advantages of the present invention.
  • a crystal nucleating agent such as talc, boron nitride, calcium carbonate or a titanium oxide in a range from 0.1 to 3% by weight.
  • the aliphatic polyester polymer concerned is a polymer that includes as the main constituent components thereof 1,4-butanediol and succinic acid.
  • an aliphatic polyester polymer specifically a product manufactured by Mitsubishi Chemical Corporation under a brand name GSPla (crystal melting point 110°C) can be preferably used. It is to be noted that for the purpose of making satisfactory the thermal bond for the formation of nonwoven fabric and making satisfactory the heat-sealing property of the obtained nonwoven fabric, it is necessary that the melting point difference between the polylactic acid polymer and the aliphatic polyester polymer be 50°C or more.
  • any aliphatic polyester polymers which do not contain isocyanate can be used as the aliphatic polyester polymer including as the main constituent components thereof 1,4-butanediol and succinic acid. Addition of isocyanate may cause a problem that aliphatic polyester polymers that contain a urethane bond are colored, or generate microgel depending on the conditions when nonwoven fabrics are formed from these polymers.
  • the aliphatic polyester polymer at a stage of being a raw material (an aliphatic polyester polymer that does not contain the below-described amide wax), preferably has the crystallization rate index (hereinafter, abbreviated as "tmax1" as the case may be) of 3 to 10 minutes as determined by the differential thermal analysis of the isothermal crystallization performed with a DSC apparatus under the conditions that the polymer is heated to 200°C at a temperature increase rate of 500°C/min, the polymer is maintained at the condition of 200°C for 5 minutes, thereafter the polymer is cooled to 90°C at a temperature decrease rate of 500°C/min and the polymer is maintained at 90°C for crystallization.
  • tmax1 crystallization rate index
  • the crystallization rate index tmax1 is indicated by the time (minutes) in which the degree of crystallization reaches half the finally reached degree of crystallization when the polymer is cooled from the molten state at 200°C and is crystallized at 90°C, and it is meant that the smaller the index is, the faster the crystallization rate is. Therefore, by using an aliphatic polyester polymer having a high crystallization rate, namely, a crystallization rate index tmax1 of 3 to 10 minutes as the aliphatic polyester polymer to be a raw material for the composite filament, the cooling performance in melt-spinning comes to be satisfactory, and the sticking can be made unlikely to occur in spreading-open.
  • the aliphatic polyester polymer at a stage of being a raw material preferably has a melt viscosity gradient, falling within a range of 10 g/10 min or less, as the difference between a melt flow rate at 230°C and a melt flow rate at 210°C, both of the melt flow rates being measured according to the method described in ASTM-D-1238(E).
  • a polymer having such a property is small in the degradation of the fluidity of the polymer due to the temperature and has a higher-order structure close to a crosslinked structure. Therefore, the crystallization rate index tmax1 can be made to be 3 to 10 minutes. Consequently, the cooling performance in melt-spinning comes to be satisfactory, and the sticking can be made unlikely to occur at the time of spreading-open.
  • the polylactic acid polymer and the aliphatic polyester polymer (the aliphatic polyester polymer that does not include the below-described amide wax) constituting the composite filament are preferably such that the melt flow rate ratio (the melt flow rate of the aliphatic polyester polymer/the melt flow rate of the polylactic acid polymer; hereinafter, abbreviated as "MFR ratio 1" as the case may be) measured at 210°C with a load of 20.2 N (2160 gf) according to the method described in ASTM-D-1238(E) is 0.3 to 1.5, and the melt flow rate ratio (the same ratio as described above; hereinafter, abbreviated as "MFR ratio 2" as the case may be) measured at 230°C with a load of 20.2 N (2160 gf) according to the method described in ASTM-D-1238(E)is 0.7 or less.
  • MFR ratio 1 melt flow rate of the aliphatic polyester polymer/the melt flow rate of the polylactic acid polymer
  • the MFR ratio 1 and the MFR ratio 2 falling within the above-described ranges enables to prevent the problem that when the composite filament is subjected to melt-spinning, the cooling of the aliphatic polyester polymer is disturbed by the heat generated when the polylactic acid polymer is crystallized. Therefore, the sticking can be made unlikely to occur in the spreading-open step subsequent to the filament cooling.
  • an amide wax is to be melt-mixed.
  • the mixing of the amide wax can attain the increase of the crystallization rate of the aliphatic polyester polymer and the effective prevention of the occurrence of the sticking in the spreading-open step through decreasing the friction resistance between filaments in the spreading-open step. Additionally, the mixing of the amide wax can attain the provision of excellent flexibility to filaments and nonwoven fabrics.
  • amide wax examples include: aliphatic carboxylic acid amides such as aliphatic monocarboxylic acid amides, N-substituted aliphatic monocarboxylic acid amides, aliphatic biscarboxylic acid amides, N-substituted aliphatic carboxylic acid bisamides and N-substituted ureas; aromatic carboxylic acid amides; and hydroxyamides each of which further contains a hydroxyl group. These compounds may include one or two or more amide groups.
  • aliphatic monocarboxylic amides include dodecanamide, palmitic acid amide, oleamide, octadecanamide, cis-13-docesenoamide, docosanamide, [R-(Z)]-12-hydroxy-9-octadecenamide, and hydroxystearamide.
  • N-substituted aliphatic monocarboxylic acid amides include N-oleylpalmitic amide, N-oleyloleamide, N-oleylstearamide, N-stearyloleamide, N-stearylstearamide, N-stearyl-cis-13-docesenoamide, methylolstearamide and methyloldocosanamide.
  • aliphatic biscarboxylic acid amides include:
  • N-substituted aliphatic carboxylic acid bisamides include dodecanamide,N,N'-1,2-ethanediylbis-, N,N'-ethylenebis(oleamide), N,N'-ethylenebis(stearamide), N,N'-methylenebis(stearamide), N,N'-ethane-1,2-diylbishexadecan-1-amide, N,N'-ethylenebis-12-hydroxystearamide, stearic acid monomethylol amide, N,N'-distearyl terephthalic acid amide and N,N'-hexamethylene-bis-12-hydroxystearyl amide.
  • N-substituted ureas include N-butyl-N'-stearyl urea, N-propyl-N'-stearyl urea, N-allyl-N'-stearyl urea and N-stearyl-N'-stearyl urea.
  • the following bisamides are preferable because of the higher capability of improving the crystallization rate: N,N'-ethylenebis(oleamide), N,N'-ethylne-bis-ricinoleyl amide, N,N'-1,2-dodecanamide,N,N'-1,2-ethanediylbis-, N,N'-ethylenebis(stearamide), N,N'-ethane-1,2-diylbishexadecan-1-amide, N,N'-ethylenebis-12-hydroxy(stearamide), N,N'-hexamethylene-bis-12-hydroxy(steramide), ethylenebis(steariamide) and ethylenebis(doecanamide).
  • the mixing amount of the amide wax to be melt-mixed with the aliphatic polyester polymer is required to be 0.1 to 1% by mass, and is preferably 0.1 to 0.7% by mass and more preferably 0.1 to 0.5% by mass.
  • the mixing amount of less than 0.1% by mass cannot reduce the friction resistance between filaments and is insufficient to suppress the occurrence of the sticking in the spreading-open step.
  • the aliphatic polyester polymer that contains an amide wax as melt-mixed therein, at a stage of being a raw material preferably has the crystallization rate index (hereinafter, abbreviated as "tmax2" as the case may be) of 2 minutes or less as determined by the differential thermal analysis of the isothermal crystallization performed with a DSC apparatus under the conditions that the polymer is heated to 200°C at a temperature increase rate of 500°C/min, the polymer is maintained at the condition of 200°C for 5 minutes to be melted, thereafter the polymer is cooled to 90°C at a temperature decrease rate of 500°C/min and the polymer is maintained at 90°C for crystallization.
  • tmax2 crystallization rate index
  • the crystallization rate index tmax2 is indicated by the time (minutes) in which the degree of crystallization reaches half the finally reached degree of crystallization when the polymer is cooled from the molten state at 200°C and is crystallized at 90°C, and it is meant that the smaller the index is, the faster the crystallization rate is. Therefore, the aliphatic polyester polymer containing an amide wax as melt-mixed therein in a predetermined amount, as a raw material of the composite filament enables the crystallization rate index tmax2 to be 2 minutes or less. Consequently, such an aliphatic polyester polymer enables to reduce the friction resistance between filaments. Consequently, the composite filament using such an aliphatic polyester is satisfactory in the cooling performance when subjected to melt-spinning, and enables the sticking to be made unlikely to occur in spreading-open.
  • the melt-mixing of the amide wax enables the melt viscosity of the aliphatic polyester polymer to be reduced although the cause for such reduction is not clear.
  • the aliphatic polyester polymer that contains no amide wax as mixed therein has suffered a problem that in the spinning step of the composite filament, sometimes increased is the viscosity of the aliphatic polyester polymer in a molten state, residing within the extruder to be subjected to spinning.
  • the present invention is free from the occurrence of such a problem, and can alleviate the phenomenon, in the spinning step, that the viscosity of the aliphatic polyester polymer in a molten state is increased. Accordingly, the melt-mixing of the amide wax enables appropriate control of the melt tension in the spinning of the composite filament. Consequently, the composite filament can be produced in a satisfactory condition without causing failures such as filament breakage.
  • the aliphatic polyester polymer preferably includes 0.1 to 1.0% by mass of an N-substituted aliphatic biscarboxylic acid amide as the amide wax.
  • a fabric having a low basis weight namely, a basis weight of 30 g/m 2 or less, can be made to be a nonwoven fabric having a remarkably excellent in hand. Accordingly, such a nonwoven fabric can be preferably used in applications in which the nonwoven fabric directly touches the skin such as applications as sanitary articles.
  • the crystallization rate of the polylactic acid polymer is slow. Consequently, at the above-described temperature (90°C) on which the crystallization rate of the aliphatic polyester polymer is measured, the isothermal crystallization of the polylactic acid polymer does not occur. Therefore, the crystallization rate of the polylactic acid polymer is inferred to be slower than the crystallization rate of the aliphatic polyester polymer.
  • the heat generated when the polylactic acid polymer having a slower crystallization rate is crystallized disturbs the cooling of the aliphatic polyester polymer forming at least a portion of the filament surface.
  • the crystallization rate of the aliphatic polyester polymer is set to fall within the above-described range, and additionally an amide wax is added to increase the crystallization rate of the aliphatic polyester polymer. Consequently, the nonwoven fabric can be produced without being disturbed by the heat generated when the polylactic acid polymer is crystallized, and without causing the sticking between filaments in the spinning step and in the spreading-open step of the composite filament.
  • the polylactic acid polymer preferably has the crystallization rate index (hereinafter, abbreviated as "tmax3" as the case may be) of 10 minutes or less as determined by the differential thermal analysis of the isothermal crystallization performed with a DSC apparatus under the conditions that the polymer is heated to 200°C at a temperature increase rate of 500°C/min, the polymer is maintained at the condition of 200°C for 5 minutes to be melted, thereafter the polymer is cooled to 130°C at a temperature decrease rate of 500°C/min and the polymer is maintained at 130°C for crystallization.
  • tmax3 crystallization rate index
  • the aliphatic polyester polymer forms at least a portion of the surface of the composite filament.
  • the filament cross sectional shape for constituting such a filament include: a side-by-side type composite cross section in which the polylactic acid polymer and the aliphatic polyester polymer are bonded to each other; a sheath-core type cross section in which the polylactic acid polymer forms the core portion and the aliphatic polyester polymer forms the sheath portion; and a division-type cross section or a multifoil-type cross section in which the polylactic acid polymer and the aliphatic polyester polymer are made to be present alternately on the filament surface.
  • the filament cross sectional shape is preferably the sheath-core type cross section in which the aliphatic polyester polymer forms the whole surface of the filament.
  • the crystallization temperature Tc1 on cooling due to the polylactic acid polymer and the crystallization temperature Tc2 on cooling due to the aliphatic polyester polymer are present.
  • Tc2 be 80°C or higher and 90°C or lower, and the heat of crystallization Hexo2 of the aliphatic polyester polymer be 30 J/g or more.
  • the crystallization temperature Tc2 on cooling due to the aliphatic polyester polymer lower than 80°C is not preferable because when the nonwoven fabric of the present invention is subjected to the heat-sealing processing as a posterior processing at such Tc2, it takes time to cool the sealing portion, so as to slow the processing speed.
  • the ratio, core portion/sheath portion exceeds 3/1, the proportion of the sheath portion comes to be too small; consequently the sheath-core type filament tends to be poor in thermobonding performance; accordingly, when the nonwoven fabric made of this sheath-core type filament retains the shape thereof through thermobonding, the shape retention property and the mechanical performances of the nonwoven fabric tend to be poor; and moreover, the nonwoven fabric made of this sheath-core type filament is unlikely to have a sufficient heat-sealing property.
  • the ratio, core portion/sheath portion is less than 1/3, the mechanical strength of the nonwoven fabric made of this sheath-core type filament is insufficient.
  • the nonwoven fabric of the present invention is a spunbond nonwoven fabric made by depositing the above-described composite filament.
  • the form of the nonwoven fabric is preferably a form in which the shape is retained through the thermobonding of the filaments to be bonded to each other due to the melting or the softening of the aliphatic polyester polymer component, and may also be a form in which the shape is retained by the entangle of the constituent filaments with each other.
  • thermobonding may be a form in which thermobonding is effected at the contact points between the filaments through the aliphatic polyester polymer being melted or softened, or may be a form in which the thermobonding portions partially formed by passing through a hot embossing device and the rest non-thermobonding portions are involved, and in the thermobonding portions, the aliphatic polyester polymer component is melted or softened to retain the shape as the nonwoven fabric.
  • the fineness of the composite filament constituting the nonwoven fabric of the present invention is preferably 2 to 11 dtex.
  • the fineness is less than 2 dtex, the spin-twisted filaments cannot withstand the stretching tension in the spinning step, and the filament breakage is frequently caused. Consequently, the operability tends to be degraded.
  • the fineness exceeds 11 dtex, the cooling performance of the spin-twisted filament tends to be poor, and thus the filaments come to be discharged from the spreading-open device in a condition of being bonded to each other by heat. Consequently, the quality of the obtained nonwoven fabric comes to be extremely poor. From these reasons, the fineness is more preferably 3 to 8 dtex.
  • the basis weight of the nonwoven fabric of the present invention has only to be appropriately selected according to the applications of the nonwoven fabric without being particularly limited; however, in general, the weight of the nonwoven fabric of the present invention is preferably in a range from 10 to 300 g/m 2 and more preferably in a range from 15 to 200 g/m 2 .
  • the basis weight is less than 10 g/m 2 , the nonwoven fabric is poor in uniformity and mechanical strength to be unpractical.
  • the weight exceeding 300 g/m 2 is disadvantageous with respect to the cost.
  • the weight of the nonwoven fabric is preferably in a range from 15 to 150 g/m 2 .
  • the weight is less than 15 g/m 2 , the number of the filaments constituting the nonwoven fabric is relatively reduced, and hence the strength of the heat-sealing portion tends to be degraded.
  • the weight exceeds 150 g/m 2 , the thickness of the nonwoven fabric is increased. Consequently, heat is not sufficiently transmitted to the inner layers in the heat-sealing portion in the heat-sealing processing, and hence such a nonwoven fabric tends to be unlikely to attain excellent heat-sealing strength.
  • a crystal nucleating agent a pigment, a thermostabilizer, an antioxidant, an antiweathering agent, a plasticizer, a lubricant, a mold-releasing agent, an antistatic agent, a filler and the like may be added.
  • the biodegradable bag-shaped article of the present invention is formed of the above-described nonwoven fabric.
  • the biodegradable bag-shaped article of the present invention is a bag-shaped article which is made to take a form of a bag by cutting the nonwoven fabric to an appropriate size and by forming the heat-sealing portions in the cut fabric.
  • the filaments are bonded to each other by the melting or the softening of the aliphatic polyester polymer, and the polylactic acid polymer is not affected by the heat and is in a condition to maintain the shape of the filament.
  • a heretofore known bag-making processing using a heat sealer can be applied.
  • the treatment conditions (preset temperature, linear pressure, treatment speed) of the heat sealer can be appropriately set such that the aliphatic polyester polymer is melted or softened, and the polylactic acid polymer having a melting point higher than the melting point of the aliphatic polyester polymer is not affected by the heat.
  • the biodegradable bag-shaped article of the present invention may be a so-called bag having a take-out opening on one side of the bag, or alternatively, may be a bag which is made to contain various contents such as an exothermic agent, a desiccant and an insect repellent, and then closed by heat-sealing so as to have no opening.
  • the biodegradable sanitary article of the present invention is formed of the above-described nonwoven fabric.
  • the nonwoven fabric used in the biodegradable sanitary article of the present invention is characterized in that the nonwoven fabric is excellent in flexibility, mechanical properties, dimensional stability and hand, and is simultaneously characterized in that when the nonwoven fabric is used in the formation of the sanitary article, thermal shrinkage of the nonwoven fabric is unlikely to occur in the heat treatment processing such as the bonding of the nonwoven fabric and other members to each other by heat-sealing or the heat-sealing processing.
  • the nonwoven fabrics used in the biodegradable sanitary article of the present invention are formed of the above-described composite filament.
  • a nonwoven fabric in which the constituent filaments bond to each other to be integrated through thermobonding and particularly preferable is a nonwoven fabric in which the constituent filaments bond through thermobonding to each other by the embossing processing.
  • the thermobonding portions the recessed portions formed in the nonwoven fabric
  • the non-thermobonding portions are substantially free from the effects of the heat and pressure. Consequently, the nonwoven fabric of the present invention comes to be a nonwoven fabric having satisfactory in hand. Additionally, such a nonwoven fabric is also satisfactory in mechanical properties and excellent in shape stability.
  • the weight of the nonwoven fabric in the sanitary article of the present invention has only to be selected according to the portions in the sanitary article in which portions the nonwoven fabric is used. Therefore, the weight of the nonwoven fabric is not particularly limited; however, in general, the weight of the nonwoven fabric is preferably 15 to 30 g/m 2 .
  • the basis weight is less than 15 g/m 2 , the number of the filaments present in a unit area is relatively reduced to give rise to a condition that holes are formed; thus, for example, when such a nonwoven fabric is used as the top sheet of a sanitary article, the back-wetting tends to occur when the sanitary article is worn, and there is a possibility that the feeling of discomfort is provoked.
  • the compression resistance thereof is preferably 40 cN or less.
  • the compression resistance exceeds 40 cN, the texture of the nonwoven fabric is stiff, and hence the portions in the sanitary article in which portions the nonwoven fabric is used tend to be limited.
  • the nonwoven fabric having a smaller value of the compression resistance is soft and desirable.
  • the lower limit of the value of the compression resistance is approximately 10 cN.
  • the nonwoven fabric in the sanitary article of the present invention is characterized in that the nonwoven fabric is unlikely to undergo thermal shrinkage when used in the sanitary article, in particular, when subjected to a heat treatment processing such as bonding to other members by heat-sealing or heat-sealing processing, and is excellent in heat treatment processability.
  • the length thermal shrinkage percentage can be made to be 2% or less, wherein Tm is the melting point of the aliphatic polyester polymer that has a melting point lower than the melting point of the polylactic acid polymer.
  • the nonwoven fabric of the present invention is produced by the spunbond method.
  • the polylactic acid polymer having a melting point of 160°C or higher, the aliphatic polyester polymer having a melting point lower, by 50°C or more, than the melting point of the polylactic acid polymer and including as the main constituent components thereof 1,4-butanediol and succinic acid, and an amide wax are prepared. Then, the polylactic acid polymer is melted, and separately the aliphatic polyester polymer and the amide wax are weighed out and mixed together and then melt-mixed in an extruder.
  • the temperature for melting is preferably in a range from (Tm + 75)°C to (Tm + 120)°C wherein Tm is the melting point of the aliphatic polyester polymer.
  • Tm is the melting point of the aliphatic polyester polymer.
  • the temperature for melting is lower than (Tm + 75)°C, the polylactic acid polymer cannot be sufficiently melted because the melting point of the polylactic acid polymer of the present invention is 160°C or higher. Therefore, such a temperature for melting is in an insufficient temperature range for performing high-speed spinning.
  • the temperature for melting exceeds (Tm + 120)°C, the heat entrained by the spin-twisted filament discharged from the spinneret is large. Therefore, the cooling capability of the aliphatic polyester polymer comes to be poor, and thus, sticking tends to occur at the time of spreading-open.
  • the spin-twisted filament discharged from the spinneret is cooled with a heretofore known cooling device such as a transverse blow cooling device or a circular blow cooling device. Thereafter, the spin-twisted filament is drawn to be made thinner by using a suction device and then taken up.
  • a heretofore known cooling device such as a transverse blow cooling device or a circular blow cooling device.
  • the drawing speed in the drawing and thinning is preferably set at 1000 to 4000 m/min, and more preferably at 1000 to 3000 m/min.
  • the drawing speed is less than 1000 m/min, no sufficient molecular orientation is promoted in the filaments, and consequently the dimensional stability of the obtained nonwoven fabric tends to be poor.
  • the drawing speed exceeds 4000 m/min, spin-twisted filaments cannot withstand the drawing tension to cause filament breakage and thus the spinning stability tends to be poor.
  • the aliphatic polyester polymer used in the present invention has a melt viscosity gradient of 20 g/10 min or less and the viscosity decrease at the temperature for melting is small; therefore, the fluidity is not improved while the drawing speed is being increased through increasing the temperature for melting as usually conducted; and thus, it is inferred that the filaments cannot withstand the drawing tension to result in the filament breakage.
  • the drawn and thinned composite filaments are subjected to spreading-open with a heretofore known spreading-open device.
  • the aliphatic polyester polymer used in the present invention is a specific polymer in which the viscosity decrease at the temperature for melting is small, and the aliphatic polyester polymer concerned has a fast crystallization rate.
  • the aliphatic polyester polymer can be satisfactorily cooled and solidified even in the production process of the spunbond nonwoven fabric in which process the distance between the spinning step and the cooling and stretching step is necessarily a limited shorter distance as compared to the production process of a staple-fiber nonwoven fabric or the like, or alternatively, even in the case where a drawing speed of around 2000 m/min is adopted in the production step of this spunbond nonwoven fabric.
  • a drawing speed of around 2000 m/min is adopted in the production step of this spunbond nonwoven fabric.
  • the filaments are deposited on the movable capture surface such as a screen conveyer to form a nonwoven web. Thereafter, it is only necessary to form a nonwoven fabric by using a heretofore known technique for forming nonwoven fabric; for example, the nonwoven web can be subjected to a heat treatment in which the filaments are subjected to mutual thermobonding by softening or melting the aliphatic polyester polymer on the filament surface.
  • thermobonding is preferably such that a partial thermocompression bonding is applied by using a thermocompression bonding device such as a hot embossing device.
  • the temperature of the roller in the embossing device has only to be set at a temperature capable of melting or softening the aliphatic polyester polymer having a lower melting point, and is appropriately selected according to the treatment time, the linear pressure or the like.
  • the surface temperature of the roller is preferably set to fall within a range from the temperature lower by 20°C than the melting point of the aliphatic polyester polymer having a lower melting point and to the melting point concerned.
  • the surface temperature of the roller is lower, preferably by 30°C or more and more preferably by 40°C or more, than the melting point of the polylactic acid polymer, for the purpose of avoiding the situation that the polylactic acid polymer as the filament-forming component is melted or softened to fail in performing the proper function thereof.
  • the temperature of the roller in the embossing device is set at a lower temperature that is lower by more than 20°C than the melting point of the aliphatic polyester polymer having a lower melting point, the aliphatic polyester polymer as the thermobonding component is not sufficiently melted or softened. Consequently, such an aliphatic polyester polymer cannot undergo sufficient bonding. Further, the nonwoven fabric formed of a composite filament including such an aliphatic polyester polymer tends to undergo strength decrease, and also tends to be fuzzed.
  • the temperature of the roller in the embossing device is set at a higher temperature that exceeds the temperature higher by 20°C than the melting point of the aliphatic polyester polymer having a lower melting point, the polylactic acid polymer tends to be readily affected by the heat, and consequently, the nonwoven fabric tends to undergo thermal shrinkage and is poor in mechanical strength as the case may be.
  • the heat treatment of the nonwoven web under the above-described temperature conditions enables the polylactic acid polymer to be heat treated at a temperature at which the polylactic acid polymer as the filament-forming component does not undergo the thermal effects such as thermal shrinkage. Consequently, such a nonwoven web is satisfactory in heat processing stability and enables the flexibility of the nonwoven fabric to be improved.
  • the polyester polymer includes as the main constituent components thereof 1,4-butanediol and succinic acid, and has a specific melting property. Consequently, there can be obtained a nonwoven fabric and a bag-shaped article which are small in thermal shrinkage at the time of thermobonding and are additionally flexible.
  • a polylactic acid polymer (brand name: U'zS-17, manufactured by Toyota Motor Corporation; hereinafter, abbreviated as "P1") having a melting point of 176°C, a MFR1 value of 22 g/10 min and a MFR2 value of 45 g/10 min was prepared as a core component.
  • An aliphatic polyester polymer (brand name: GSPla, FZ71PD, manufactured by Mitsubishi Chemical Corporation; hereinafter abbreviated as "P2") having a melting point of 114°C, a MFR3 value of 22 g/10 min and a MFR4 value of 25 g/10 min, and including 1,4-butanediol and succinic acid as the constituent components was prepared.
  • the crystallization rate index tmax1 of the aliphatic polyester polymer was 7.4 minutes.
  • a master batch in which P1 was used as a base and 20% by mass of talc (TA) as a crystal nucleating agent was contained as kneaded with P1 was prepared.
  • melt-spinning was performed by using a spinneret capable of forming a sheath-core type filaments cross section in such a way that P1 formed the core portion and the P2 formed the sheath portion, at a mass out flow rate each orifice of 0.70 g/min.
  • the spin-twisted filaments were cooled with a heretofore known cooling device, thereafter successively drawn for thinning at a drawing speed of 1900 m/min with an air sucker disposed under the spinneret, subjected to spreading-open with a heretofore known fiber opening device and captured and deposited as web on the moving screen conveyer.
  • a heretofore known cooling device disposed under the spinneret
  • spreading-open with a heretofore known fiber opening device and captured and deposited as web on the moving screen conveyer.
  • the fineness of the deposited composite filament was found to be 3.6 dtex.
  • the web was made to pass for heat treatment through a embossing device composed of an embossing roller and a metal roller having a flat surface, and thus a nonwoven fabric having a weight of 20 g/m 2 was obtained.
  • the embossing conditions were such that the surface temperature of each of both rollers was set at 100°C, the embossing roller had a sculptural pattern composed of circles each having an area of 0.6 MM 2 , the pressure bonding point density was 20 points/cm 2 , and the proportion of the pressure bonding area was 15%.
  • amide waxes listed in Table 1 are specifically as follows:
  • a polylactic acid polymer (brand name: 6201D, manufactured by NatureWorks LLC; hereinafter, abbreviated as "P3") having a melting point of 168°C, a MFR1 value of 20 g/10 min and a MFR2 value of 40 g/10 min was prepared as a core component.
  • the melting temperature in the melt extruder was set at 220°C and the drawing speed was set at 2250 m/min, and thus a composite filament having the fineness of 3.1 dtex was obtained.
  • the surface temperature of each of both rollers was set at 90°C. Otherwise in the same manner as in Example 1, a nonwoven fabric was obtained.
  • the amount of the amide wax contained in P3 was set at 0.3% by mass. Otherwise in the same manner as in Example 2, a nonwoven fabric was obtained.
  • Example 2 As compared to Example 1, the amide wax contained in P2 was altered to N,N'-ethylenebis-12-hydroxystearamide. Otherwise in the same manner as in Example 1, a nonwoven fabric was obtained.
  • Example 2 P3 was prepared as a core component. Additionally, as compared to Example 2, the single hole discharge rate was set at 1.6 g/min, the drawing speed was set at 2000 m/min and the fineness was set at 7.4 dtex. Otherwise in the same manner as in Example 2, a nonwoven fabric was obtained.
  • Example 2 As compared to Example 2, the amide wax was altered to N,N'-ethane-1.2-diylbishexadecan-1-amide. Otherwise in the same manner as in Example 2, a nonwoven fabric was obtained.
  • each of the nonwoven fabrics of Examples 1 to 8 included a polylactic acid polymer and an aliphatic polyester polymer, the aliphatic polyester polymer included as the constituent components thereof 1,4-butanediol and succinic acid, and the melting point of the aliphatic polyester polymer was lower, by 50°C or more, than the melting point of the polylactic acid polymer. Therefore, each of the nonwoven fabrics of Examples 1 to 8 was excellent in the stability at the heat processing and in the heat sealing property.
  • the aliphatic polyester polymer included the amide wax in a content of 0.1 to 1.0% by mass, and consequently the friction between the filaments at the spreading-open was able to be diminished. Thus, webs satisfactory in spreading-open property were able to be produced, and hence nonwoven fabrics satisfactory in flexibility were able to be obtained.
  • P1 was used as the core component and P2 was used as the sheath component, and no additive was added to the sheath component.
  • P1 was prepared as the core component.
  • aliphatic polyester polymer brand name: GSPla, AZ71TN, manufactured by Mitsubishi Chemical Corporation; hereinafter abbreviated as "P5"
  • P5 aliphatic polyester polymer having a melting point of 110°C, a MFR3 value of 26 g/10 min and a MFR4 value of 52 g/10 min, and including as the constituent components thereof an aliphatic diol and an aliphatic dicarboxylic acid and being copolymerized with lactic acid.
  • the crystallization rate index tmax1 of this aliphatic polyester polymer was unable to be detected. In other words, this aliphatic polyester polymer was allowed to stand under the measurement conditions for 60 minutes, but no crystallization peak was detected.
  • a master batch in which P1 was used as a base and 20% by mass of talc (TA) as a crystal nucleating agent was contained as kneaded with P1 was prepared.
  • P1 and P5 were respectively melted at 200°C with separate melt extruders.
  • melt-spinning was performed by using a spinneret capable of forming a sheath-core type filament cross section in such a way that P1 formed the core portion and the P5 formed the sheath portion, at a single hole discharge rate of 0.70 g/min.

Claims (8)

  1. Vliesstoff, der durch ein Spunbond-Verfahren aus Verbundfilamenten ausgebildet ist, wobei:
    das Verbundfilament ein Polymilchsäurepolymer mit einem Schmelzpunkt von nicht unter 160 °C und ein aliphatisches Polyesterpolymer umfasst, das einen Schmelzpunkt aufweist, der um nicht weniger als 50 °C niedriger als der Schmelzpunkt des Polymilchsäurepolymers ist;
    das aliphatische Polyesterpolymer zumindest einen Abschnitt einer Filamentoberfläche ausbildet; und
    das aliphatische Polyesterpolymer als Bestandskomponenten davon 1,4-butanediol und Bernsteinsäure umfasst und gleichzeitig 0,1 bis 1 Masse-% eines Amidwachses umfasst.
  2. Vliesstoff nach Anspruch 1, wobei der Stoff aus Verbundfilamenten ausgebildet ist, die Mantel-Kern-Filamente sind, bei denen das Polymilchsäurepolymer einen Kernabschnitt davon ausbildet und das aliphatische Polyesterpolymer einen Mantelabschnitt davon ausbildet, und ein Verbundverhältnis zwischen dem Kernabschnitt und dem Mantelabschnitt eine Beziehung erfüllt, die Kernabschnitt/Mantelabschnitt = 3/1 zu 1/3 pro Massenverhältnis lautet.
  3. Vliesstoff nach Anspruch 1, wobei:
    wenn Differentialthermoanalyse auf einer Temperaturabfallrate von 10 °C/Minute nach dem Durchführen des Schmelzens auf einer Temperaturanstiegsrate von 10 °C/Minute ausgeführt wird, eine Kristallisierungstemperatur Tc1 bei Abkühlen aufgrund des Polymilchsäurepolymers und eine Kristallisierungstemperatur Tc2 bei Abkühlen aufgrund des aliphatischen Polyesterpolymers vorliegen;
    Tc2 nicht niedriger als 80 °C und nicht höher als 90 °C ist; und
    eine Kristallisierungswärme von Hexo2 des aliphatischen Polyesterpolymers nicht niedriger als 30 J/g ist.
  4. Erzeugungsverfahren für einen Vliesstoff, folgende Schritte umfassend:
    Fertigen eines Polymilchsäurepolymers mit einem Schmelzpunkt von nicht unter 160 °C und eines aliphatischen Polyesterpolymers, das als Bestandskomponenten davon 1,4-butanediol und Bernsteinsäure umfasst und das einen Schmelzpunkt aufweist, der um nicht weniger als 50 °C niedriger als der Schmelzpunkt des Polymilchsäurepolymers ist;
    derartiges Mischen eines Amidwachses, dass es einen Gehalt von 0,1 bis 1 Masse-% in dem aliphatischen Polyesterpolymer aufweist;
    separates Schmelzen des Polymilchsäurepolymers und des aliphatischen Polyesterpolymers auf einer Temperatur von (Tm + 75) °C bis (Tm + 120) °C, wobei Tm der Schmelzpunkt des aliphatischen Polyesterpolymers ist;
    Ausführen von Spinnen unter Benutzung einer Verbundspinndüse, die es ermöglicht, dass das aliphatische Polyesterpolymer zumindest einen Abschnitt einer Filamentoberfläche in einem Filamentquerschnitt ausbildet;
    Abkühlen, Ziehen und anschließendes Ausbreiten von Filamenten, die aus der Spinndüse verdrillt gesponnen wurden; und
    Ausbilden eines Vliesspinnstoffs durch Ablagern der dadurch erhaltenen Filamente.
  5. Erzeugungsverfahren für einen Vliesstoff nach Anspruch 4, wobei als das aliphatische Polyesterpolymer ein Polymer benutzt wird, das einen Kristallisierungsratenindex von 3 bis 10 Minuten nach Bestimmung durch eine Differentialthermoanalyse einer isothermischen Kristallisierung aufweist, die unter den Bedingungen durchgeführt wird, dass das Polymer auf 200 °C mit einer Temperaturanstiegsrate von 500 °C/Minute erhitzt wird, das Polymer für 5 Minuten auf 200 °C gehalten wird, das Polymer danach auf 90 °C mit einer Temperaturabfallrate von 500 °C/Minute abgekühlt wird, und das Polymer zur Kristallisierung auf 90 °C gehalten wird, und einen Schmelzviskositätsgradienten von nicht mehr als 20 g/10 Minuten aufweist, der als Differenz zwischen einem Schmelzfließindex auf 230 °C mit einer Last von 20,2 N (2160 gf) und einem Schmelzfließindex von 210 °C mit einer Last von 20,2 N (2160 gf) erhalten wird, wobei beide der Schmelzfließindizes gemäß einem in ASTM-D-1238(E) beschrieben Verfahren gemessen werden.
  6. Erzeugungsverfahren für einen Vliesstoff nach Anspruch 4, wobei als das Polymilchsäurepolymer und das aliphatische Polyesterpolymer diese zwei Polymere benutzt werden, für die ein Schmelzfließindexverhältnis, das auf 210 °C mit einer Last von 20,2 N (2160 gf) gemäß dem in ASTM-D-1238(E) beschriebenen Verfahren gemessen wird, eine Beziehung erfüllt, dass der Schmelzfließindex des aliphatischen Polyesterpolymers/der Schmelzfließindex des Polymilchsäurepolymers = 0,3 bis 1,5 ist, und ein Schmelzfließindexverhältnis, das auf 230 °C mit einer Last von 20,2 N (2160 gf) gemäß dem in ASTM-D-1238(E) beschriebenen Verfahren gemessen wird, eine Beziehung erfüllt, dass der Schmelzfließindex des aliphatischen Polyesterpolymers/der Schmelzfließindex des Polymilchsäurepolymers = nicht mehr als 0,7 ist.
  7. Biologisch abbaubarer, beutelförmiger Gegenstand, der aus dem Vliesstoff nach Anspruch 1 ausgebildet ist, und dem es ermöglicht ist, durch Versehen desselben mit einem Heißsiegelabschnitt eine beutelförmige Struktur anzunehmen, in welchem Bestandteilsfilamente aufgrund von Schmelzen oder Erweichen des aliphatischen Polyesterpolymers aneinander gebondet sind.
  8. Biologisch abbaubarer Gegenstand, der aus dem Vliesstoff nach Anspruch 1 ausgebildet ist.
EP20090167764 2009-05-29 2009-08-13 Vliesstoff aus polymilchsäurefilament und dessen herstellungsverfahren Not-in-force EP2261410B1 (de)

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US10590577B2 (en) 2016-08-02 2020-03-17 Fitesa Germany Gmbh System and process for preparing polylactic acid nonwoven fabrics
US11441251B2 (en) 2016-08-16 2022-09-13 Fitesa Germany Gmbh Nonwoven fabrics comprising polylactic acid having improved strength and toughness

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DE102013014918A1 (de) * 2013-07-15 2015-01-15 Ewald Dörken Ag Bikomponentenfaser zur Herstellung von Spinnvliesen
CZ2021234A3 (cs) * 2021-05-14 2022-11-23 Pfnonwovens Holding S.R.O. Netkaná textilie se zvýšenou pevností

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JP3355026B2 (ja) 1994-05-18 2002-12-09 カネボウ株式会社 熱融着性ポリ乳酸繊維
JPH07133511A (ja) 1993-11-10 1995-05-23 Toyobo Co Ltd 生分解性複合繊維及びそれを用いた不織布
JP4573622B2 (ja) * 2004-10-25 2010-11-04 ユニチカ株式会社 生分解性不織布およびその製造方法
JP4873979B2 (ja) 2005-04-04 2012-02-08 ユニチカ株式会社 ポリ乳酸系長繊維不織布およびその製造方法
JP4650206B2 (ja) 2005-10-25 2011-03-16 チッソ株式会社 生分解性複合繊維、および、これを用いた繊維構造物と吸収性物品
DE602005023671D1 (de) * 2005-12-15 2010-10-28 Kimberly Clark Co Biologisch abbaubare mehrkomponentenfasern

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Publication number Priority date Publication date Assignee Title
US10590577B2 (en) 2016-08-02 2020-03-17 Fitesa Germany Gmbh System and process for preparing polylactic acid nonwoven fabrics
US11441251B2 (en) 2016-08-16 2022-09-13 Fitesa Germany Gmbh Nonwoven fabrics comprising polylactic acid having improved strength and toughness

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