Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
  • D06M13/10—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
  • D06M13/184—Carboxylic acids; Anhydrides, halides or salts thereof
  • D06M13/207—Substituted carboxylic acids, e.g. by hydroxy or keto groups; Anhydrides, halides or salts thereof
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
  • D06M13/10—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
  • D06M13/224—Esters of carboxylic acids; Esters of carbonic acid
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
  • D06M13/10—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
  • D06M13/224—Esters of carboxylic acids; Esters of carbonic acid
  • D06M13/2243—Mono-, di-, or triglycerides
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
  • D06M13/244—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing sulfur or phosphorus
  • D06M13/282—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing sulfur or phosphorus with compounds containing phosphorus
  • D06M13/292—Mono-, di- or triesters of phosphoric or phosphorous acids; Salts thereof
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
  • D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
  • D06M13/325—Amines
  • D06M13/342—Amino-carboxylic acids; Betaines; Aminosulfonic acids; Sulfo-betaines
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
  • D06M15/647—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain containing polyether sequences
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
  • D06M2101/16—Synthetic fibres, other than mineral fibres
  • D06M2101/18—Synthetic fibres consisting of macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M2101/20—Polyalkenes, polymers or copolymers of compounds with alkenyl groups bonded to aromatic groups
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
  • D06M2200/25—Resistance to light or sun, i.e. protection of the textile itself as well as UV shielding materials or treatment compositions therefor; Anti-yellowing treatments
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
  • Y10T428/2913—Rod, strand, filament or fiber
  • Y10T428/2933—Coated or with bond, impregnation or core
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/603—Including strand or fiber material precoated with other than free metal or alloy
  • Y10T442/607—Strand or fiber material is synthetic polymer

Definitions

• the present invention relates to fibers having an excellent color fastness and excellent liquid absorption properties. Moreover, the invention relates to a fibrous formed body, for example, anonwoven fabric, using the fibers having the excellent color fastness and the excellent liquid absorption properties.
• Heat-fusible fibers formable by heat fusion are widely used for hygienic goods such as a diaper, a napkin and an absorbent pad, daily necessities, an industrial material such as a filter, and so forth because a nonwoven fabric having a good feeling can be easily obtained with a high safety by utilizing heat energy from hot air, heat rolls or the like.
• hygienic goods such as a diaper, a napkin and an absorbent pad
• an industrial material such as a filter
• high liquid absorption properties are required from necessity of quickly and repeatedly absorbing a liquid such as urine and menstrual blood.
• an antioxidant such as dibutylhydroxytoluene is added and contained in the heat-fusible fibers obtained according to relevant methods for the purpose of preventing deterioration by generation of radicals. Therefore, discoloration is easily caused if the fibers are stored in sunshine, directly under a fluorescent lamp, or the like for a long period of time, and thus a problem of deteriorating a quality level of a product frequently arises.
• Patent literature No.1 a proposal has been made for improving color fastness by adding hydroxycarboxylic acid to a fiber treating agent to be attached onto a fiber surface.
• Patent literature No.2 a proposal has been made for the purpose of preventing a yellowing phenomenon generated during manufacturing or storing fibers by using an alkyl ammonium phosphate for a fiber treating agent.
• hydroxycarboxylic acid has a low function of giving hydrophilic properties, and therefore may adversely affect liquid absorption properties of the fibers.
• alkyl ammonium phosphate has a low function of giving durable hydrophilic properties, and therefore has a problem of difficulty in obtaining highly durable hydrophilic properties.
• liquid absorption properties means a capability of quickly transferring a liquid to an absorption layer in the case where the liquid such as urine and menstrual blood is brought in contact (dripped or the like) from a side of a nonwoven fabric under a state where a fibrous formed body such as the nonwoven fabric is arranged on the absorption layer such as a pulp sheet.
• the liquid absorption properties are also referred to as liquid permeability, fluid permeability or the like.
• durable hydrophilic properties means repeated liquid absorption properties herein.
• a subject of the invention is to provide fibers and a fibrous formed body, particularly, a nonwoven fabric all having an exceptional color fastness, and high liquid absorption properties and high durable hydrophilic properties.
• the inventors of the invention have diligently continued research, as a result, have found that the subject can be attained by attaching to fibers a fiber treating agent containing a predetermined amount of each of an alkyl phosphate metal salt, a trialkylglycine derivative and hydroxycarboxylic acid.
• the invention includes the constitutions described below.
• fibers having excellent liquid absorption properties and excellent durable hydrophilic properties, and having an excellent color fastness are obtained by attaching to fibers a fiber treating agent containing a predetermined amount of each of an alkyl phosphate metal salt, a trialkylglycine derivative and hydroxycarboxylic acid.
• a fibrous formed body for example, a nonwoven fabric can be attained as constituted of such fibers and having excellent liquid absorption properties and excellent durable hydrophilic properties, and having an excellent color fastness.
• the invention allows a preferred compatibility of liquid absorption properties, durable hydrophilic properties and color fastness in the fibers and the fibrous formed body.
• Component (A) constituting a fiber treating agent to be attached to fibers according to the invention is an alkyl phosphate metal salt in which the number of carbons of an alkyl group is less than 10.
• the number of carbons of the alkyl group is preferably in the range of 4 to 8, further preferably, in the range of 6 to 8.
• Specific examples of the metal salt include an alkali metal salt.
• Specific examples of the alkali metal salt include a sodium salt, a potassium salt and a lithium salt, preferably, a potassium salt among the salts.
• Component (B) constituting the fiber treating agent to be attached to the fibers according to the invention is a trialkylglycine derivative, and a compound having an inner salt between a carboxyl group and quaternary ammonium in which three alkyl groups are bonded with a nitrogen atom in a glycine molecular structure, or the compound having a so-called betaine structure.
• component (B) is composed of alkyl groups arbitrarily selected from alkyl groups having 1 to 22 carbons.
• Compound (B) has particularly preferably two alkyl groups being a lower alkyl group having up to 4 carbons such as methyl and ethyl, and one alkyl group being a long-chain alkyl group having 12 or more carbons.
• Specific examples of the trialkylglycine derivative include dimethyloctadecylglycine hydroxide and heptadecylimidazolium hydroxyethylglycine hydroxide.
• Component (C) constituting the fiber treating agent to be attached to the fibers according to the invention is hydroxycarboxylic acid.
• Specific examples of the hydroxycarboxylic acid include citric acid, lactic acid, tartaric acid, malic acid and glycolic acid, particularly preferably, citric acid.
• a component ratio of each of component (A), component (B) and component (C) all constituting the fiber treating agent to be attached to the fibers according to the invention is in the range of 3% by mass or more to less than 10% by mass in an effective component in the fiber treating agent. More specifically, the component ratios (% by mass) of component (A) and component (C) are required to satisfy a relationship: component (C) ⁇ component (A). The component ratio (% by mass) of each component of component (A), component (B) and component (C) further preferably satisfies a relationship: component (C) ⁇ component (B) ⁇ component (A).
• Hydroxycarboxylic acid as component (C) has an effect on improving color fastness. If the component ratio of hydroxycarboxylic acid as component (C) is in the range of 3% by mass or more to less than 10% by mass, the effect on improving the color fastness is sufficient, and simultaneously liquid absorption properties are not extremely decreased.
• the component ratio of hydroxycarboxylic acid as component (C) is preferably in the range of 3 to 5% by mass.
• the alkyl phosphate metal salt in which the number of carbons of the alkyl group is less than 10 as component (A) is needed as a component for compensating for a decrease in the liquid absorption properties.
• the alkyl phosphate metal salt in which the number of carbons of the alkyl group is less than 10 is the component for maintaining and improving the liquid absorption properties.
• the component ratio thereof is in the range of 3% by mass or more to less than 10% by mass based on the effective component in the fiber treating agent.
• Component (A) is in the above range, and thus durable hydrophilic properties are not adversely affected.
• the component ratio is further preferably in the range of 5% by mass or more to less than 10% by mass.
• the relationship of the component ratio of each of the alkyl phosphate metal salt in which the number of carbons of the alkyl group is less than 10 as component (A), and hydroxycarboxylic acid as component (C) both constituting the fiber treating agent is required to satisfy the relationship: component (C) ⁇ component (A) in the relationship of the composition ratios (% by mass) of component (A) and component (C) because component (A) compensates for a decrease in the liquid absorption properties caused by adding component (C) as described above.
• the trialkylhydroxyglycine derivative as component (B) is a component for giving the durable hydrophilic properties, and the component ratio thereof is in the range of 3% by mass or more to less than 10% by mass based on the effective component in the fiber treating agent.
• the component (B) compensates for a decrease in the durable hydrophilic properties caused by adding the alkyl phosphate metal salt as component (A).
• Component (B) is in the above component ratio, and thus good durable hydrophilic properties can be given, and the color fastness is not decreased, either.
• Component (B) has further preferably a composition ratio in the range of 3 to 7% by mass.
• the component ratios among the trialkylhydroxyglycine derivative as component (B), the alkyl phosphate metal salt in which the number of carbons of the alkyl group is less than 10 as component (A), and the hydroxycarboxylic acid as component (C) further preferably satisfy the relationship: component (C) ⁇ component (B) ⁇ component (A) in the component ratio (% by mass) of each component in view of the color fastness, the liquid absorption properties and the durable hydrophilic properties.
• effective component means a component excluding water content from the whole of the fiber treating agent.
• Component (D) constituting the fiber treating agent to be attached to the fibers according to the invention is the alkyl phosphate metal salt in which the number of carbons of the alkyl group is in the range of 10 to 14.
• component (D) is a component for giving the liquid absorption properties and antistatic properties in a manner similar to component (A)
• component (D) has a larger number of carbons than component (A) has, and therefore has a role of assisting a component for improving smoothness of a fiber surface and giving the durable hydrophilic properties in addition to giving the liquid absorption properties.
• the number of carbons of the alkyl group is in the range of 10 to 14, and thus the liquid absorption properties are not significantly decreased.
• Specific examples of the metal salt include an alkali metal salt.
• Specific examples of the alkali metal salt include a sodium salt, a potassium salt and a lithium salt, preferably, the potassium salt among the salts.
• the component ratio of the alkyl phosphate metal salt as component (D) is in the range of 40 to 60% by mass, further preferably, in the range of 45 to 55% by mass in the effective component in the fiber treating agent.
• a specific embodiment of the fibers according to the invention includes fibers containing a fiber treating agentattached to fibers further containing component (E) described below in the range of 10 to 20% by mass and component (F) described below in the range of 15 to 25% by mass, in terms of the component ratio based on the effective component.
• Component (E) constituting the fiber treating agent to be attached to the fibers according to the invention is polyoxyalkylene-modified silicone, preferably, represented by the general formula described below.
• R represents methylene, propylene, N-(aminomethyl)methylimino or N-(aminopropyl)propylimino
• X represents a polyoxyalkylene group.
• n and m indicate integers, respectively, selected from numbers in such a range that content of Si is in the range of 20 to 70% by mass and molecular weight is in the range of 1,000 to 100,000.
• the content of Si in the modified silicone is in the range of 20 to 70% by mass.
• Specific examples of the polyoxyalkylene group include a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, and a group in which the above constitutive monomers are copolymerized.
• the modified silicone contains at least 20% by mass of a polyoxyethylene moiety relative to a polyoxyalkylene moiety.
• the modified silicone has the molecular weight preferably in the range of 1,000 to 100,000, particularly preferably, in the range of 7,000 to 15,000 in view of giving hydrophilic properties.
• the component ratio of component (E) in the fiber treating agent is suitably in the range of 10 to 20% by mass.
• component ratio of component (E) is in the range of 10 to 20% by mass, sufficient hydrophilic properties are developed and a quick water permeability is acquired. Furthermore, the amount of wetback is also suppressed, no decrease of durable hydrophilic properties is caused, and no dropping of the treating agent from the fibers by water permeation or the like easily occurs.
• Component (F) constituting the fiber treating agent to be attached to the fibers according to the invention is an ester of an alkyleneoxide adduct of hydroxystearic acid glyceride with maleic acid, wherein the ester is a compound in which a hydroxyl group of the ester is blocked with monocarboxylic acid having 10 to 22 carbons.
• the alkyleneoxide adduct of hydroxystearic acid glyceride is obtained by allowing an addition reaction of alkyleneoxide to an ester composed of hydroxystearic acid and glycerin being a polyhydric alcohol.
• Component (F) is the ester of the compound with maleic acid, in which the reaction molar ratio thereof is preferably in the range of 1.5 : 1.0 to 2.0 : 1.0, and the hydroxyl group of the ester is blocked with monocarboxylic acid having 10 to 22 carbons such as lauric acid and stearic acid.
• component (F) Molecular weight of component (F) is large to give durability to the treating agent by the action thereof, and can suppress dropping of other highly hydrophilic components from the fiber surface by water permeation or the like.
• the component ratio of component (F) in the fiber treating agent is suitably in the range of 15 to 25% by mass. If the component ratio of component (F) is in the above range, the durable hydrophilic properties are good, the hydrophilic properties due to the treating agent are maintained and resistance to liquid absorption is not increased.
• the effective component in the fiber treating agent described above is suitably attached to the fibers in the range of 0.1 to 1.0% by mass, preferably, in the range of 0.3 to 0.8% by mass based on the mass of the fibers.
• the amount of attachment to the fibers is 0.1% by mass or more, antistatic properties are preferably sufficiently developed, and no static electricity is preferably generated in a process for processing the fibers having the attached fiber treating agent into the fibrous formed body such as the nonwoven fabric, and thus processing preferably tends to be facilitated.
• the amount of attachment is 1.0% by mass or less, dropping of the fiber treating agent from the fibers is preferably small, accumulation in equipment is preferably not increased, and thus processability is preferably not deteriorated in the process for processing the fibers.
• the fiber treating agent may be attached to the fibers, and then the fibers may be processed into the fibrous formed body as required.
• the fibers are processed into the fibrous formed body, and then the fiber treating agent may be attached to the fibrous formed body.
• the fibrous formed body for example, the nonwoven fabric, according to the invention can be processed and manufactured according to a suitable process using the fibers to which the above fiber treating agent is attached, or can be manufactured by attaching the above fiber treating agent to the fibrous formed body obtained by being processed from the fibers according to a suitable process.
• the fiber treating agent may be clearly attached uniformly to the whole body, may be attached to an arbitrary part as required, or may be attached in a different amount for each part to be attached.
• the fiber treating agent can be attached to the fibers or the fibrous formed body such as the nonwoven fabric in a state of emulsion in which the fiber treating agent is diluted with ion exchange water or the like in a concentration in the range of 3 to 30% by mass.
• the fiber treating agent may be attached to the fibers in a process for producing the fibers, namely, a so-called spinning process, drawing process or crimp process, or the fiber treating agent may be attached to the nonwoven fabric to be in a desired range in the amount of attachment after the fibers are processed into the fibrous formed body, for example, after the fibers are processed into the nonwoven fabric.
• a method for attaching the fiber treating agent to the fibers publicly known methods such as an oiling roll method, a dipping method and a spraying method can be applied. Specific examples of a method for attaching the fiber treating agent to the nonwoven fabric include an oiling roll method (coating method), a dipping method and a spraying method. For improving efficiency and fixing properties of attachment, corona discharge treatment or normal-pressure plasma discharge treatment may be applied to the nonwoven fabric as pretreatment.
• Adjustment of the amount of the fiber treating agent attached to the fibers or the fibrous formed body can be carried out with the number of roll rotations or the like in the case where the fiber treating agent is attached with a roll such as an oiling roll, or with.a spraying amount or the like in the case where the fiber treating agent is attached by the spraying method.
• Specific examples of methods for quantitatively confirming the amount of the fiber treating agent attached to the fibers include an extraction method using a solvent.
• the amount of the attached fiber treating agent per unit mass can be confirmed by dipping a predetermined amount of the fibers or the fibrous formed body into a solvent, for example, methanol, ethanol or 2-propanol, in which the fiber treating agent intended for confirming the amount of attachment is soluble, evaporating only the solvent with heat or the like and measuring the remaining amount.
• Specific examples include a rapid method and a Soxhlet method.
• surfactant components can be used for the fiber treating agent to be attached to the fibers according to the invention within the range in which advantageous effects of the invention are not adversely affected.
• specific examples of the surfactant components include an antistatic agent such as sodium alkanesulfonate, and a nonionic component such as sorbitan acid ester.
• additives can be mixed with the fiber treating agent to be attached to the fibers according to the invention within the range in which advantageous effects of the invention are not adversely affected.
• specific examples of the additives include an emulsifier, a preservative, an anti-rust agent, a pH regulator and an antifoaming agent.
• the fibers according to the invention may be single-component fibers or conjugate fibers.
• a thermoplastic resin constituting the fibers is not particularly limited. Specific examples include a polyolef in resin such as high density polyethylene, linear low density polyethylene, low density polyethylene, polypropylene (propylene homopolymer), an ethylene-propylene copolymer composed mainly of propylene, an ethylene-propylene-1-butene copolymer composed mainly of propylene, polybutene-1, polyhexene-1, polyoctene-1, poly-4-methylpentene-1, polymethylpentene, 1,2-polybutadiene and 1,4-polybutadiene, and a polyester resin such as polyethylene terephthalate, polypropylene terephthalate, polybutyrene terephthalate, polylactic acid, polybutylene succinate, polybutylene adipate terephthalate and a copolymerized polyester (copolyester).
• conjugate fibers include conjugate fibers having a concentric sheath-core structure, an eccentric sheath-core structure and a side-by-side structure as a cross-sectional structure, and split conjugate fibers having an alternating radial shape.
• a shape of the fibers include a round, star, elliptic, triangular, quadrangular, pentagonal, multifoil or hollow shape.
• combinations of resins for the conjugate fibers includes high density polyethylene/polypropylene, low density polyethylene/polypropylene, an ethylene-octene copolymer/polypropylene, an ethylene-propylene copolymer/polypropylene, an ethylene-propylene-butene-1 copolymer/polypropylene, high density polyethylene/polyethylene terephthalate, an ethylene-octene copolymer/polyethylene terephthalate, an ethylene-propylene-butene-1 copolymer/polyethylene terephthalate, polypropylene/polyethylene terephthalate, high density polyethylene/polybutyrene terephthalate and polylactic acid/polybutylene succinate.
• a ratio of the sheath/core or the low-melting point component/high-melting point component is preferably in the range of 10/90 to 90/10 in a mass ratio, particularly preferably, in the range of 30/70 to 70/30 in view of spinnability, drawing properties and nonwoven fabric processability.
• an additive such as an antioxidant, a light stabilizer, an ultraviolet light absorber, a neutralizer and a nucleating agent may be further added appropriately as required within the range in which advantageous effects of the invention are not adversely affected.
• An antibacterial agent, a flame retardant, a smoothing agent, an antistatic agent, a pigment, and inorganic particulates for giving flexibility may be added to the fibers according to the invention appropriately as required within the range in which advantageous effects of the invention are not adversely affected.
• Specific examples of methods for addition include a method for directly adding powder thereof or a method for preparing a masterbatch from the powder and kneading the masterbatch.
• a resin used for preparing the masterbatch a resin identical to the thermoplastic resin constituting the fibers is most preferably used, but the resin is not particularly limited thereto, and a different resin may also be used if the resin meets requirements of the invention.
• the fibers according to the invention can be suitably obtained by a melt spinning method or a spunbond method each using the resin containing the thermoplastic resin described above, for example.
• the fibers can be obtained by obtaining undrawn fibers according to the melt spinning method, promoting partial orientation and crystallization in a drawing process, giving crimp in a crimp process, applying heat treatment for a fixed period of time at a predetermined temperature using a hot-air dryer or the like, and then cutting the obtained product into an arbitrary length.
• a denier of the fibers according to the invention is not particularly limited, but preferably is in the range of 0.3 to 12.0 dtex.
• the denier is, further preferably, in the range of 1.0 to 8.0 dtex, still further preferably, in the range of 1.2 to 6.0 dtex in view of a process for processing the fibers into the nonwoven fabric.
• Length of the fibers according to the invention is not particularly limited, and can be determined arbitrarily for each method for processing the fibers into the nonwoven fabric.
• the length of the fibers is preferably in the range of 25 to 125 millimeters, further preferably, in the range of 38 to 76 millimeters.
• the length of the fibers is preferably in the range of 3 to 25 millimeters, further preferably, in the range of 3 to 12 millimeters.
• a method for processing the fibers into the nonwoven fabric is not particularly limited.
• a technique is preferably used in which the fiber web is formed, and then heat treatment is performed to thermally bond entangled points of the fibers constituting the fiber web, and to process the fibers into the nonwoven fabric.
• Specific examples of the method for forming the fiber web include a carding method for allowing the fibers to pass through the roller carding machine, an air-laid method for forming the fiber web by means of air and a spunbond method for laminating long fibers.
• publicly known machines can be used, such as a hot-air circulation dryer, a hopper-type heat-treatment machine, a relaxing hot-air dryer, a Yankee dryer, a drum dryer, an infra-red dryer and a partial thermocompression bonding processing machine.
• Unit weight (mass per unit area) of the nonwoven fabric in the case of processing the fibers according to the invention into the nonwoven fabric is not particularly limited, and can be determined according to an intended application.
• the unit weight of a surface material of a disposable diaper and a sanitary napkin is preferably in the range of 10 to 50 g/m 2 , further preferably, in the range of 20 to 35 g/m 2 .
• the fibrous formed body according to the invention comprises, in addition to the nonwoven fabric as described above, a fibrous tow, a fiber web, a fibrous laminate, a net, a knitted or woven fabric, and a material processed into a sheet or mass by heat-treating the above bodies, and a material prepared by superimposing nonwoven fabrics in a layer or waveform and applying secondary processing such as heat treatment.
• Specific examples of the fibrous formed body according to the invention include the nonwoven fabric, in particular.
• the fibers or the fibrous formed body according to the invention can be applied to various textile products.
• thermoplastic resin (Thermoplastic resin)
• thermoplastic resin constituting fibers A resin described below was used as a thermoplastic resin constituting fibers.
• a melt mass-flow rate was measured in accordance with JIS K7210.
• MI was measured in accordance with condition D (testing temperature: 190°C, load: 2.16kg)
• MFR was measured in accordance with condition M (testing temperature: 230°C, load: 2.16 kg), in Table 1 of Appendix A.
• the fibers were dried by means of a hot-air circulation dryer and cut into a length of 51 millimeters by means of a cutter, and thus short fibers were obtained.
• Examples 1 to 7 and Comparative Examples 1 to 4 were carried out by attaching the fiber treating agent to the fibers, and Examples 8 and 9 and Comparative Example 5 were carried out by attaching the fiber treating agent to a nonwoven fabric as described later.
• compositions of fiber treating agents used in each example were shown in Table 1 and Table 2. Units of the compositions were expressed in terms of % by mass, and the total amount of effective components in the fiber treating agents should be 100% by mass.
• Examples 1 to 7 and Comparative Examples 1 to 4 short fibers obtained in the above process were processed into a fiber web by means of a roller carding test machine (made by Daiwa-kiko corporation Ltd.), and the web was subjected to thermal bonding by through-air processing (abbreviated as TA in Tables 1 and 2) at a temperature described in Table 1 and Table 2 by using a suction dryer.
• TA through-air processing
• Example 8 short fibers obtained without attaching a fiber treating agent in manufacturing the fibers were processed into a fiber web by means of a roller carding test machine (made by Daiwa-Kiko corporation Ltd.), and the web was subjected to thermal bonding by through-air processing (abbreviated as TA) at a temperature described in Table 2 by using a suction dryer.
• TA through-air processing
• Example 9 and Comparative Example 5 a spunbond nonwoven fabric was obtained according to a spunbond method using a resin described in Table 2. Specifically, a spinnerette allowing a concentric sheath-core cross section was used, and an extrusion output was adjusted to be 50/50 in a volume ratio in a fiber cross section at an extrusion temperature described in Table 2. A group of composite long fibers output from the spinnerette was introduced into an air sucker, sucked and drawn, and processed into fibers having a fiber diameter of 2.2 dtex.
• the group of the long fibers discharged from the air sucker was charged by giving electric charges with charging apparatus, opened by collision with a reflector, and a group of opened long fibers was collected, as a long fiber web, on an endless net conveyer provided with a suction device on a rear face.
• the collected long fiber web was subjected to partial thermocompression bonding processing (abbreviated as PB in Table 2) with an embossing roll (projection) having a compression bonding area ratio of 21%/flat roll at a linear pressure of 80 N/mm.
• PB in Table 2 partial thermocompression bonding processing
• the nonwoven fabrics were dipped into an emulsion of the fiber treating agent shown in Table 2, the nonwoven fabrics were dehydrated and dried so as to contain a predetermined amount of attachment.
• the fibers were processed into a carded web by means of a roller carding test machine, and the web was processed into a nonwoven fabric having a unit weight of 200 plus minus 20 g/m 2 by a needle-punch processing method.
• the nonwoven fabric was cut into a 8 cm long and 8 cm wide piece, and the cut piece was used as a test sample.
• the nonwoven fabric was cut into 80 mm long and 80 mm wide pieces, and the pieces were superimposed to be 200 plus minus 20 g/m 2 in the total unit weight, and the superimposed pieces were used as a test sample.
• the test sample was placed at 80 centimeters above an oil stove fire source (ambient temperature: 100 ⁇ 5°C), and exposed to combustion gas for 3 hours. Then the sample was removed.
• test results were rated as described below. If a numerical value of ⁇ YI was 6 or less, color fastness was exceptional and therefore rated as 'A'. If the numerical value is in the range of 7 to 8, the color fastness was rated as 'B', but if the numerical value is 9 or more, color change may be judged high, and thus the color fastness was rated as 'C'.
• results of liquid absorption tests were rated by classifying the results into three levels according to a period of time required for liquid absorption as described below.
• Results of a third absorption test were considered as an indicator of durable hydrophilic properties, and rated by classifying the results into three levels according to a period of time required for liquid absorption as described below.
• Example 1 Example 2
• Example 3 Example 4
• Example 5 Example 6
• Example 7 Thermoplastic resin (abbreviation/ extrusion temperature (°C) Core ingredient PP-1 (260) PP-3 (270) PP-3 (270) PP-3 (270) PP-3 (270) PP-3 (270) PP-3 (270) PP-3 (270) PP-3 (270) Sheath ingredient PE-1 (240) co-PP (250) co-PP (250) co-PP (250) Co-PP (250) co-PP (250) co-PP (250) co-PP (250)
• Volume ratio core/sheath
• Fibers according to the invention have both an excellent color fastness, and excellent liquid absorption properties and excellent durable hydrophilic properties as obtained by attaching a fiber treating agent containing a predetermined amount of an alkyl phosphate metal salt, a trialkylglycine derivative and hydroxycarboxylic acid.
• a fiber treating agent containing a predetermined amount of an alkyl phosphate metal salt, a trialkylglycine derivative and hydroxycarboxylic acid.
• better fibers can be provided by further attaching, as an effective component in a fiber treating agent, polyoxyalkylene-modified silicone, and an ester of an alkyleneoxide adduct of hydroxystearic acid glyceride with maleic acid, wherein the ester is a compound in which a hydroxyl group of the ester is blocked with monocarboxylic acid.
• a fibrous formed body such as a nonwoven fabric constituted of the fibers according to the invention has high liquid absorption properties and high durable hydrophilic properties, and exceptional color fastness.
• the fibrous formed body can be advantageously used for applications of various textile products including an absorbent article such as a diaper, a napkin and an incontinence pad, a medical and sanitary material such as a gown and a surgical gown, an indoor interior material such as a wall sheet, shoj i paper and a floor material, a life-related material such as cover cloth, a cleaning wiper and a kitchen garbage cover, a toiletry product such as a disposable toilet and a toilet cover, a pet product such as a pet sheet, a pet diaper and a pet towel, an industrial material such as a wiping material, a filter, a cushioning material, an oil adsorbent and an ink tank adsorbent, a general medical material, a bedding material and a nursing care product.

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• Engineering & Computer Science (AREA)
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• Chemical Kinetics & Catalysis (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Nonwoven Fabrics (AREA)

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