EP2952617A1 - Fibrous nonwoven fabric - Google Patents
Fibrous nonwoven fabric Download PDFInfo
- Publication number
- EP2952617A1 EP2952617A1 EP14745725.3A EP14745725A EP2952617A1 EP 2952617 A1 EP2952617 A1 EP 2952617A1 EP 14745725 A EP14745725 A EP 14745725A EP 2952617 A1 EP2952617 A1 EP 2952617A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- nonwoven fabric
- resin composition
- low
- crystalline polyolefin
- crystalline
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 103
- 238000002425 crystallisation Methods 0.000 claims abstract description 69
- 229920000098 polyolefin Polymers 0.000 claims abstract description 64
- 239000011342 resin composition Substances 0.000 claims abstract description 60
- 239000000835 fiber Substances 0.000 claims description 72
- 238000000465 moulding Methods 0.000 claims description 13
- -1 polypropylene Polymers 0.000 description 75
- 239000004743 Polypropylene Substances 0.000 description 69
- 229920001155 polypropylene Polymers 0.000 description 68
- 238000000034 method Methods 0.000 description 53
- 239000003795 chemical substances by application Substances 0.000 description 31
- 229920005989 resin Polymers 0.000 description 31
- 239000011347 resin Substances 0.000 description 31
- 230000008025 crystallization Effects 0.000 description 20
- 238000005259 measurement Methods 0.000 description 17
- 238000002844 melting Methods 0.000 description 14
- 230000008018 melting Effects 0.000 description 14
- 238000012360 testing method Methods 0.000 description 14
- 239000000203 mixture Substances 0.000 description 13
- 238000001816 cooling Methods 0.000 description 12
- UAUDZVJPLUQNMU-KTKRTIGZSA-N erucamide Chemical compound CCCCCCCC\C=C/CCCCCCCCCCCC(N)=O UAUDZVJPLUQNMU-KTKRTIGZSA-N 0.000 description 12
- 238000009987 spinning Methods 0.000 description 12
- 239000000463 material Substances 0.000 description 10
- 230000003068 static effect Effects 0.000 description 10
- 239000004711 α-olefin Substances 0.000 description 10
- 238000010438 heat treatment Methods 0.000 description 9
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
- 239000000654 additive Substances 0.000 description 8
- 229910052751 metal Chemical class 0.000 description 8
- 239000002184 metal Chemical class 0.000 description 8
- 239000000600 sorbitol Substances 0.000 description 8
- 125000004432 carbon atom Chemical group C* 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 7
- 238000009826 distribution Methods 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- 150000003839 salts Chemical class 0.000 description 7
- FMZUHGYZWYNSOA-VVBFYGJXSA-N (1r)-1-[(4r,4ar,8as)-2,6-diphenyl-4,4a,8,8a-tetrahydro-[1,3]dioxino[5,4-d][1,3]dioxin-4-yl]ethane-1,2-diol Chemical compound C([C@@H]1OC(O[C@@H]([C@@H]1O1)[C@H](O)CO)C=2C=CC=CC=2)OC1C1=CC=CC=C1 FMZUHGYZWYNSOA-VVBFYGJXSA-N 0.000 description 6
- 229920001577 copolymer Polymers 0.000 description 6
- 230000000996 additive effect Effects 0.000 description 5
- 238000007599 discharging Methods 0.000 description 5
- 230000014509 gene expression Effects 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 4
- GJWSUKYXUMVMGX-UHFFFAOYSA-N citronellic acid Chemical compound OC(=O)CC(C)CCC=C(C)C GJWSUKYXUMVMGX-UHFFFAOYSA-N 0.000 description 4
- 229940087101 dibenzylidene sorbitol Drugs 0.000 description 4
- 238000005227 gel permeation chromatography Methods 0.000 description 4
- 230000000704 physical effect Effects 0.000 description 4
- 229920005672 polyolefin resin Polymers 0.000 description 4
- 229920001296 polysiloxane Polymers 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- PBKONEOXTCPAFI-UHFFFAOYSA-N 1,2,4-trichlorobenzene Chemical compound ClC1=CC=C(Cl)C(Cl)=C1 PBKONEOXTCPAFI-UHFFFAOYSA-N 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- 239000006096 absorbing agent Substances 0.000 description 3
- 238000013016 damping Methods 0.000 description 3
- 239000011810 insulating material Substances 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 239000002759 woven fabric Substances 0.000 description 3
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 2
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 2
- CRSBERNSMYQZNG-UHFFFAOYSA-N 1-dodecene Chemical compound CCCCCCCCCCC=C CRSBERNSMYQZNG-UHFFFAOYSA-N 0.000 description 2
- GQEZCXVZFLOKMC-UHFFFAOYSA-N 1-hexadecene Chemical compound CCCCCCCCCCCCCCC=C GQEZCXVZFLOKMC-UHFFFAOYSA-N 0.000 description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 2
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 2
- HFDVRLIODXPAHB-UHFFFAOYSA-N 1-tetradecene Chemical compound CCCCCCCCCCCCC=C HFDVRLIODXPAHB-UHFFFAOYSA-N 0.000 description 2
- ULQISTXYYBZJSJ-UHFFFAOYSA-N 12-hydroxyoctadecanoic acid Chemical compound CCCCCCC(O)CCCCCCCCCCC(O)=O ULQISTXYYBZJSJ-UHFFFAOYSA-N 0.000 description 2
- XDOFQFKRPWOURC-UHFFFAOYSA-N 16-methylheptadecanoic acid Chemical compound CC(C)CCCCCCCCCCCCCCC(O)=O XDOFQFKRPWOURC-UHFFFAOYSA-N 0.000 description 2
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 2
- 239000005711 Benzoic acid Substances 0.000 description 2
- FBPFZTCFMRRESA-JGWLITMVSA-N D-glucitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-JGWLITMVSA-N 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- UHOVQNZJYSORNB-MZWXYZOWSA-N benzene-d6 Chemical compound [2H]C1=C([2H])C([2H])=C([2H])C([2H])=C1[2H] UHOVQNZJYSORNB-MZWXYZOWSA-N 0.000 description 2
- WPYMKLBDIGXBTP-UHFFFAOYSA-N benzoic acid Chemical compound OC(=O)C1=CC=CC=C1 WPYMKLBDIGXBTP-UHFFFAOYSA-N 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 238000001460 carbon-13 nuclear magnetic resonance spectrum Methods 0.000 description 2
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 2
- 239000011538 cleaning material Substances 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- UKMSUNONTOPOIO-UHFFFAOYSA-N docosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCCCCC(O)=O UKMSUNONTOPOIO-UHFFFAOYSA-N 0.000 description 2
- POULHZVOKOAJMA-UHFFFAOYSA-N dodecanoic acid Chemical compound CCCCCCCCCCCC(O)=O POULHZVOKOAJMA-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 229910052731 fluorine Inorganic materials 0.000 description 2
- 239000011737 fluorine Substances 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- IPCSVZSSVZVIGE-UHFFFAOYSA-N hexadecanoic acid Chemical compound CCCCCCCCCCCCCCCC(O)=O IPCSVZSSVZVIGE-UHFFFAOYSA-N 0.000 description 2
- 229920001519 homopolymer Polymers 0.000 description 2
- 239000003112 inhibitor Substances 0.000 description 2
- 239000012212 insulator Substances 0.000 description 2
- 229920002521 macromolecule Polymers 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 2
- UTOPWMOLSKOLTQ-UHFFFAOYSA-N octacosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCCCCCCCCCCC(O)=O UTOPWMOLSKOLTQ-UHFFFAOYSA-N 0.000 description 2
- CCCMONHAUSKTEQ-UHFFFAOYSA-N octadec-1-ene Chemical compound CCCCCCCCCCCCCCCCC=C CCCMONHAUSKTEQ-UHFFFAOYSA-N 0.000 description 2
- 230000036961 partial effect Effects 0.000 description 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 229920001384 propylene homopolymer Polymers 0.000 description 2
- 239000008262 pumice Substances 0.000 description 2
- 230000002829 reductive effect Effects 0.000 description 2
- 238000005070 sampling Methods 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 1
- FUSNPOOETKRESL-ZPHPHTNESA-N (z)-n-octadecyldocos-13-enamide Chemical compound CCCCCCCCCCCCCCCCCCNC(=O)CCCCCCCCCCC\C=C/CCCCCCCC FUSNPOOETKRESL-ZPHPHTNESA-N 0.000 description 1
- 229940114072 12-hydroxystearic acid Drugs 0.000 description 1
- 238000001644 13C nuclear magnetic resonance spectroscopy Methods 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 1
- 235000021357 Behenic acid Nutrition 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- ORAWFNKFUWGRJG-UHFFFAOYSA-N Docosanamide Chemical compound CCCCCCCCCCCCCCCCCCCCCC(N)=O ORAWFNKFUWGRJG-UHFFFAOYSA-N 0.000 description 1
- 102100037815 Fas apoptotic inhibitory molecule 3 Human genes 0.000 description 1
- 101000878510 Homo sapiens Fas apoptotic inhibitory molecule 3 Proteins 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- 239000005639 Lauric acid Substances 0.000 description 1
- 238000005481 NMR spectroscopy Methods 0.000 description 1
- 229920003355 Novatec® Polymers 0.000 description 1
- 239000005642 Oleic acid Substances 0.000 description 1
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 1
- 235000021314 Palmitic acid Nutrition 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000004902 Softening Agent Substances 0.000 description 1
- 235000021355 Stearic acid Nutrition 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 235000010724 Wisteria floribunda Nutrition 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- ZGNIGAHODXRWIT-UHFFFAOYSA-K aluminum;4-tert-butylbenzoate Chemical compound [Al+3].CC(C)(C)C1=CC=C(C([O-])=O)C=C1.CC(C)(C)C1=CC=C(C([O-])=O)C=C1.CC(C)(C)C1=CC=C(C([O-])=O)C=C1 ZGNIGAHODXRWIT-UHFFFAOYSA-K 0.000 description 1
- CSJKPFQJIDMSGF-UHFFFAOYSA-K aluminum;tribenzoate Chemical compound [Al+3].[O-]C(=O)C1=CC=CC=C1.[O-]C(=O)C1=CC=CC=C1.[O-]C(=O)C1=CC=CC=C1 CSJKPFQJIDMSGF-UHFFFAOYSA-K 0.000 description 1
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- 159000000032 aromatic acids Chemical class 0.000 description 1
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- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
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- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 238000011088 calibration curve Methods 0.000 description 1
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- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
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- SWSBIGKFUOXRNJ-CVBJKYQLSA-N ethene;(z)-octadec-9-enamide Chemical compound C=C.CCCCCCCC\C=C/CCCCCCCC(N)=O.CCCCCCCC\C=C/CCCCCCCC(N)=O SWSBIGKFUOXRNJ-CVBJKYQLSA-N 0.000 description 1
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- RLAWWYSOJDYHDC-BZSNNMDCSA-N lisinopril Chemical compound C([C@H](N[C@@H](CCCCN)C(=O)N1[C@@H](CCC1)C(O)=O)C(O)=O)CC1=CC=CC=C1 RLAWWYSOJDYHDC-BZSNNMDCSA-N 0.000 description 1
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- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
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- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
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- 239000002516 radical scavenger Substances 0.000 description 1
- WBHHMMIMDMUBKC-XLNAKTSKSA-N ricinelaidic acid Chemical compound CCCCCC[C@@H](O)C\C=C\CCCCCCCC(O)=O WBHHMMIMDMUBKC-XLNAKTSKSA-N 0.000 description 1
- 229960003656 ricinoleic acid Drugs 0.000 description 1
- FEUQNCSVHBHROZ-UHFFFAOYSA-N ricinoleic acid Natural products CCCCCCC(O[Si](C)(C)C)CC=CCCCCCCCC(=O)OC FEUQNCSVHBHROZ-UHFFFAOYSA-N 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- KYKFCSHPTAVNJD-UHFFFAOYSA-L sodium adipate Chemical compound [Na+].[Na+].[O-]C(=O)CCCCC([O-])=O KYKFCSHPTAVNJD-UHFFFAOYSA-L 0.000 description 1
- 239000001601 sodium adipate Substances 0.000 description 1
- 235000011049 sodium adipate Nutrition 0.000 description 1
- ZHROMWXOTYBIMF-UHFFFAOYSA-M sodium;1,3,7,9-tetratert-butyl-11-oxido-5h-benzo[d][1,3,2]benzodioxaphosphocine 11-oxide Chemical compound [Na+].C1C2=CC(C(C)(C)C)=CC(C(C)(C)C)=C2OP([O-])(=O)OC2=C1C=C(C(C)(C)C)C=C2C(C)(C)C ZHROMWXOTYBIMF-UHFFFAOYSA-M 0.000 description 1
- VOJOXNPTBDGNQO-UHFFFAOYSA-M sodium;1h-pyrrole-2-carboxylate Chemical compound [Na+].[O-]C(=O)C1=CC=CN1 VOJOXNPTBDGNQO-UHFFFAOYSA-M 0.000 description 1
- LKYIPGJOXSVWPX-UHFFFAOYSA-M sodium;thiophene-2-carboxylate Chemical compound [Na+].[O-]C(=O)C1=CC=CS1 LKYIPGJOXSVWPX-UHFFFAOYSA-M 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 125000003011 styrenyl group Chemical class [H]\C(*)=C(/[H])C1=C([H])C([H])=C([H])C([H])=C1[H] 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
-
- 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
- D04H3/007—Addition polymers
-
- 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
- D04H3/016—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2501/00—Wearing apparel
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2509/00—Medical; Hygiene
- D10B2509/02—Bandages, dressings or absorbent pads
- D10B2509/026—Absorbent pads; Tampons; Laundry; Towels
-
- 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]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
-
- 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]
- Y10T442/681—Spun-bonded nonwoven fabric
Definitions
- the present invention relates to a fibrous nonwoven fabric using a polyolefin material.
- polyolefin-based fibers and nonwoven fabrics are used for various applications, such as a disposable diaper, a sanitary product, a hygienic product, a clothing material, a bandage, a packaging material, etc.
- the fibers and nonwoven fabrics are often used for applications in which they come into direct contact with the body, and thus, in recent years, a required performance regarding good wear feeling to the body and hand touch feeling are being more increased. For this reason, with respect to the nonwoven fabrics, technological development related to an improvement of texture for good wear feeling, reduction in basis weight for weight reduction of products, and the like is demanded.
- PTL 1 discloses a spunbonded nonwoven fabric using a resin composition containing a low-crystalline polypropylene and a high-crystalline polypropylene; however, from the viewpoint of providing a nonwoven fabric having more excellent flexibility and higher strength, fibers constituting the nonwoven fabric are required to more reduce fiber diameter.
- the present invention has been made, and its object is to reduce fiber diameter of fibers constituting a fibrous nonwoven fabric using a polyolefin resin composition while preserving spinning stability.
- the present inventors made extensive and intensive investigations. As a result, it has been found that the above-described problem is solved by using a polyolefin resin composition having a specified crystallization rate.
- the present invention provides the following.
- the reduction of diameter of fibers constituting the nonwoven fabric can be achieved while preserving spinning stability.
- a fibrous nonwoven fabric of a first invention is composed of a resin composition containing a high-crystalline polyolefin (A) and a low-crystalline polyolefin (B).
- the low-crystalline polyolefin (B) as referred to in the present invention means a crystalline polyolefin having a longer half-crystallization time than the high-crystalline polyolefin (A). That is, a half-crystallization time (t a ) of the high-crystalline polyolefin (A) and a half-crystallization time (t b ) of the low-crystalline polyolefin (B) satisfy a relation of t a ⁇ t b .
- the high-crystalline polyolefin (A) which is used in the first invention is not particularly limited in terms of a kind thereof so long as it satisfies a condition (2) regarding a resin composition (C) as described later.
- Examples thereof include polyethylene, a propylene homopolymer, an ethylene-propylene copolymer, an ethylene- ⁇ -olefin copolymer, a propylene- ⁇ -olefin copolymer, an ⁇ -olefin homopolymer, a copolymer of plural ⁇ -olefins, and the like.
- This ⁇ -olefin is preferably one having 4 to 24 carbon atoms, more preferably one having 4 to 12 carbon atoms, and especially preferably one having 4 to 8 carbon atoms.
- its initial elastic modulus is preferably 500 to 2,000 MPa, more preferably 600 to 2,000 MPa, and still more preferably 700 to 1,800 MPa.
- the initial elastic modulus as referred to in this description is one measured by the following measuring method.
- a press sheet having a thickness of 1 mm was fabricated.
- a test piece was sampled from the resulting press sheet in conformity with JIS K7113 (2002) No. 2-1/2.
- a tensile tester (AUTOGRAPH AG-1, manufactured by Shimadzu Corporation)
- the test piece was set at an initial length L0 of 40 mm, stretched at a tensile speed of 100 mm/min, and measured for a strain and a load in the stretching process, and the initial elastic modulus was calculated according to the following expression.
- Initial elastic modulus N Load N at a strain of 5 % / 0.05
- the half-crystallization time (t a , t b , and t c ) as referred to in this description means one measured by the following measuring method.
- the measurement is made using FLASH DSC (manufactured by Mettler-Toledo International Inc.) in the following method.
- the above-described low-crystalline polyolefin (B) is not particularly limited in terms of a kind thereof so long as it has a longer half-crystallization time than the high-crystalline polyolefin (A) as described above.
- Examples thereof include polyethylene, a propylene homopolymer, an ethylene-propylene copolymer, a propylene- ⁇ -olefin copolymer, an ⁇ -olefin homopolymer, a copolymer of plural ⁇ -olefins, and the like.
- This ⁇ -olefin is preferably one having 4 to 24 carbon atoms, more preferably one having 4 to 12 carbon atoms, and especially preferably one having 4 to 8 carbon atoms.
- its initial elastic modulus is preferably 5 MPa or more and less than 500 MPa, more preferably 10 to 400 MPa, and still more preferably 20 to 300 MPa.
- the initial elastic modulus of the low-crystalline polyolefin (B) can be measured in the same manner as that in the above-described high-crystalline polyolefin (A).
- the low-crystalline polyolefin (B) is preferably a low-crystalline polypropylene satisfying the following condition (a), and more preferably a low-crystalline polypropylene satisfying all of the following conditions (a) to (f).
- the above-described low-crystalline polypropylene its [mmmm] (mesopentad fraction) is 20 to 60 mol%.
- the [mmmm] is 20 mol% or more, solidification after melting is fast, stickiness of the fibers is suppressed, and attachment onto a wind-up roll is hardly caused, and therefore, continuous molding becomes easy.
- the [mmmm] is 60 mol% or less, a degree of crystallization is lowered, and therefore, end breakage is hardly caused, and furthermore, a nonwoven fabric having a soft touch feeling is obtained.
- the [mmmm] of the above-described low-crystalline polypropylene is more preferably 30 to 50 mol%, and still more preferably 40 to 50 mol%.
- the above-described low-crystalline polypropylene its [rrrr]/(1 - [mmmm]) is preferably 0.1 or less.
- the [rrrr]/(1 - [mmmm]) is an index indicating the uniformity of regularity distribution of the low-crystalline polypropylene.
- the resultant does not become a mixture of a high-stereoregular polypropylene and an atactic polypropylene, as in the conventional polypropylene which is produced using an existent catalyst system, and stickiness is hardly caused.
- the [rrrr]/(1 - [mmmm]) of the above-described low-crystalline polypropylene is more preferably 0.05 or less, and still more preferably 0.04 or less.
- the above-described low-crystalline polypropylene its [rmrm] (racemic-meso-racemic-meso pentad fraction) is preferably more than 2.5 mol%. If the [rmrm] is 2.5 mol% or less, random properties of the low-crystalline polypropylene are reduced, the degree of crystallization is increased due to crystallization by an isotactic polypropylene block chain, end breakage is caused, and furthermore, a soft touch feeling is not obtained in the resulting nonwoven fabric.
- the [rmrm] of the above-described low-crystalline polypropylene is more preferably 2.6 mol% or more, and still more preferably 2.7 mol% or more. An upper limit thereof is usually about 10 mol%.
- the [mm] (mesotriad fraction) ⁇ [rr] (racemic triad fraction)/[mr] (meso-racemic triad fraction) 2 is preferably 2.0 or less.
- the [mm] ⁇ [rr]/[mr] 2 indicates an index of random properties of the polymer, and when the [mm] ⁇ [rr]/[mr] 2 is smaller, the random properties become higher, the frequency of end breakage is reduced, and a nonwoven fabric having a soft touch feeling is obtained. When this value is 2.0 or less, end breakage is not caused in fibers obtained by spinning, and a nonwoven fabric having a good soft touch feeling is obtained.
- the [mm] ⁇ [rr]/[mr] 2 of the above-described low-crystalline polypropylene is more preferably more than 0.25 and 1.8 or less, and still more preferably 0.5 to 1.5.
- the weight average molecular weight of the above-described low-crystalline polypropylene is preferably 10,000 to 200,000.
- the weight average molecular weight is 10,000 or more, the viscosity of the low-crystalline polypropylene is not excessively low but is appropriate, and therefore, end breakage on the occasion of spinning is suppressed.
- the weight average molecular weight is 200,000 or less, the viscosity of the low-crystalline polypropylene is not excessively high, and spinnability is improved.
- the weight average molecular weight of the above-described low-crystalline polypropylene is more preferably 30,000 to 100,000, and still more preferably 40,000 to 80,000.
- the low-crystalline polypropylene which is used in the first invention its molecular weight distribution (Mw/Mn) is preferably less than 4.0.
- Mw/Mn molecular weight distribution
- the molecular weight distribution (Mw/Mn) of the above-described low-crystalline polypropylene is more preferably 3.0 or less, and still more preferably 2.5 or less.
- the low-crystalline polypropylene satisfying the above-described condition (a) may also be a copolymer using other comonomer than propylene so long as it satisfies the condition (2) regarding the resin composition (C) as described later.
- the amount of the comonomer is usually 2% by mass or less.
- the comonomer include ethylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicocene, and the like. In the present invention, one or two or more kinds of these monomers can be used.
- the resin composition (C) which is a raw material of the fibrous nonwoven fabric of the first invention, contains the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B) as described above, and a half-crystallization time (t c ) of the resin composition (C) is 1.2 to 2.0 times the half-crystallization time (t a ) of the high-crystalline polyolefin (A).
- the half-crystallization time (t c ) is less than 1.2 times the half-crystallization time (t a )
- the crystallization rate of the resin composition (C) is fast, and on the occasion of melt molding of fibers, and the molten resin discharged from a nozzle is immediately crystallized, and therefore, end breakage is liable to occur, reducing the fiber diameter is difficultly achieved, and the fiber diameter is limited to 1.7 deniers or more.
- the half-crystallization time (t c ) is more than 2.0 times the half-crystallization time (t a )
- the fiber surface is sticky, roping (phenomenon in which the fibers stick to each other) is generated, and stable spinning cannot be achieved.
- the fibers become thick due to shrinkage, so that reducing the fiber diameter cannot be achieved, too.
- the half-crystallization time (t c ) is preferably 1.2 to 1.9 times, and more preferably 1.3 to 1.9 times the half-crystallization time (t a ).
- Examples of a method of controlling the half-crystallization time (t c ) of the resin composition (C) to 1.2 times or more the half-crystallization time (t a ) of the high-crystalline polyolefin (A) include a method of increasing a ratio of the low-crystalline polyolefin (B) in the combination of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B); a method of changing the low-crystalline polyolefin (B) to one having a longer half-crystalline time (t b ); and the like.
- examples of a method of controlling the half-crystallization time (t c ) of the resin composition (C) to 2.0 times or less the half-crystalline time (t a ) of the high-crystalline polyolefin (A) include a method of decreasing a ratio of the low-crystalline polyolefin (B) in the combination of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B); a method of changing the low-crystalline polyolefin (B) to one having a shorter half-crystalline time (t b ); and the like.
- the content of the high-crystalline polyolefin (A) in the above-described resin composition (C) is not particularly limited so long as it falls within the range where the condition (2) regarding the resin composition (C) can be satisfied.
- the contents of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B) in order to satisfy the condition (2) regarding the resin composition (C) vary depending upon what kinds of polyolefins are selected with respect to the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B).
- the content of the high-crystalline polyolefin (A) in the above-described resin composition (C) is preferably 50 to 98% by mass, and more preferably 60 to 95% by mass.
- the content of the low-crystalline polyolefin (B) in the above-described resin composition (C) is preferably 2 to 50% by mass, and more preferably 5 to 40% by mass.
- the content of the low-crystalline polypropylene satisfying the above-described initial elastic modulus is preferably 2 to 35% by mass, any more preferably 5 to 30% by mass on the basis of a total sum of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B).
- the above-described resin composition (C) may contain other thermoplastic resin and various additives, such as a release agent, etc. so long as it satisfies the above-described physical properties.
- thermoplastic resin examples include olefin-based polymers. Specifically, examples thereof include a polypropylene, a propylene-ethylene copolymer, a propylene-ethylene-diene copolymer, a polyethylene, an ethylene/ ⁇ -olefin copolymer, an ethylene-vinyl acetate copolymer, a hydrogenated styrene-based elastomer, and the like. These may be used solely or may be used in combination of two or more kinds thereof.
- the above-described release agent refers to an additive for improving release properties such that the molded nonwoven fabric does not attach to a roll or a conveyor of a molding machine.
- the release agent which is contained in the resin composition (C) is called an internal release agent, and the internal release agent refers to an additive for improving release properties of the nonwoven fabric upon being added to the resin raw material.
- An external release agent as described later refers to an additive for improving release properties of the nonwoven fabric upon being coated directly on a roll or a conveyor of a molding machine.
- Examples of the internal release agent include organic carboxylic acids or metal salts thereof, aromatic sulfonic acid salts or metal salts thereof, organic phosphoric acid compounds or metal salts thereof, dibenzylidene sorbitol or derivatives thereof, rhodinic acid partial metal salts, inorganic fine particles, imidic acids, amide acids, quinacridones, quinones, and mixtures thereof.
- Examples of the metal in the above-described metal salt of an organic carboxylic acid include Li, Ca, Ba, Zu, Mg, Al, Pb, and the like.
- examples of the carboxylic acid include fatty acids, such as octylic acid, palmitic acid, lauric acid, stearic acid, behenic acid, montanic acid, 12-hydroxystearic acid, oleic acid, isostearic acid, ricinoleic acid, etc.; and aromatic acids, such as benzoic acid, p-t-b-benzoic acid, etc.
- Specific examples thereof include aluminum benzoate, aluminum p-t-butylbenzoate, sodium adipate, sodium thiophenecarboxylate, sodium pyrrolecarboxylate, and the like.
- dibenzylidene sorbitol or derivative thereof include dibenzylidene sorbitol, 1,3:2,4-bis(o-3,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-2,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-ethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-chlorobenzylidene)sorbitol, 1,3:2,4-dibenzylidene sorbitol, and the like. More specifically, GELOL MD and GELOL MD-R, all of which are manufactured by New Japan Chemical Co., Ltd., and the like are exemplified.
- Examples of the above-described rhodinic acid partial metal salt include PINECRYSTAL KM1600, PINECRYSTAL KM1500, and PINECRYSTAL KM1300, all of which are manufactured by Arakawa Chemical Industries, Ltd., and the like.
- Examples of the above-described inorganic fine particle include talc, clay, mica, asbestos, glass fiber, glass flake, glass bead, calcium silicate, montmorillonite, bentonite, graphite, aluminum powder, alumina, silica, diatomaceous earth, titanium oxide, magnesium oxide, pumice powder, pumice balloon, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite, molybdenum sulfide, and the like.
- synthetic silica may be used as the silica, and examples thereof include SYLYSIA, manufactured by Fuji Silysia Chemical Ltd., MIZUKASIL, manufactured by Mizusawa Industrial Chemicals, Ltd., and the like.
- amide compound examples include erucic acid amide, oleic acid amide, stearic acid amide, behenic acid amide, ethylene bisstearic acid amide, ethylene bisoleic acid amide, stearyl erucamide, oleyl palmitamide, adipic acid dianilide, suberic acid dianilide, and the like.
- organic phosphoric metal salt examples include ADEKASTAB NA-11 and ADEKASTAB NA-21, all of which are manufactured by Adeka Corporation, and the like.
- These internal release agents can be used solely or in combination of two or more kinds thereof.
- the content of the internal release agent is preferably 10 to 10,000 ppm by mass, and more preferably 100 to 5,000 ppm by mass on the basis of the resin mixture from which the additives are eliminated.
- the content of the internal release agent is 10 ppm by mass or more, the function as the release agent is revealed, whereas when it is 10,000 ppm by mass or less, a balance between the function as the release agent and the economy becomes good.
- any conventionally known additives may be blended.
- the additive include a foaming agent, a crystal nucleating agent, a weatherability stabilizer, a UV absorber, a light stabilizer, a heat resistance stabilizer, an antistatic agent, a flame retardant, a synthetic oil, a wax, an electric property-improving agent, a slip inhibitor, an anti-blocking agent, a viscosity-controlling agent, a coloring inhibitor, a defogging agent, a lubricant, a pigment, a dye, a plasticizer, a softening agent, an age resistor, a hydrochloric acid-absorbing agent, a chlorine scavenger, an antioxidant, and an antitack agent, and the like.
- the nonwoven fabric of the first invention is one obtained by using the above-described resin composition (C) as the raw material, and preferably one produced by a spunbond method.
- the nonwoven fabric is produced in such a manner that a melt-kneaded resin composition is spun, stretched, and opened to form continuous long fibers, and subsequently, in a continued step, the continuous long fibers are accumulated on a moving collecting surface and entangled.
- a nonwoven fabric can be produced continuously, and the resulting nonwoven fabric has large strength because fibers constituting the nonwoven fabric are stretched continuous long fibers.
- Fibers can be produced by extruding a molten polymer, for example, from a large nozzle with several thousands of holes or a group of small nozzles having, for example, about 40 holes. After discharged from the nozzle, molten fibers are cooled by a cross-flow cooling air system, drawn away from the nozzle, and stretched by high-speed airflow. Generally, there are two kinds of air-damping methods, and the both use a venturi effect. In the first air-damping method, filaments are stretched by using a suction slot (slot stretching). This method is conducted by using the width of a nozzle or the width of a machine.
- filaments are stretched through a nozzle or a suction gun.
- the filaments formed through the above methods are collected to form a web on a screen (wire) or a hole forming belt.
- the web passes through a compression roll and then passes between heating calendar rolls, and the web is bounded in a portion where an embossment portion on one roll includes about 10% to 40% of the area of the web, thereby forming a nonwoven fabric.
- the fibers of the resulting fibrous nonwoven fabric are likely to become a fine fiber with 1.3 deniers or less; when it is 0.2 or less, the above-described fibers are likely to become a fine fiber with 1.0 denier or less; when it is 0.13 or less, the above-described fibers are likely to become a fine fiber with 0.8 deniers or less; and when it is 0.1 or less, the above-described fibers are likely to become a fine fiber with 0.6 deniers or less.
- the fibrous nonwoven fabric of the present invention by a spunbonded nonwoven fabric molding machine using a cabin system
- reducing the fiber diameter can be achieved to an extent that the fiber diameter is 1.0 denier or less.
- the fibers of the resulting fibrous nonwoven fabric are likely to become a fine fiber with 1.3 deniers or less; when it is 0.06 or less, the above-described fibers are likely to become a fine fiber with 1.0 denier or less; and when it is 0.05 or less, the above-described fibers are likely to become a fine fiber with 0.9 deniers or less.
- the external release agent is sprayed onto the above-described moving collecting surface.
- the resin composition (C) contains the internal release agent, though the external release agent may not be sprayed onto the above-described moving collecting surface, it may also be used in combination with the internal release agent from the standpoint of obtaining good release properties.
- the above-described external release agent include fluorine-based release agents and silicone-based release agents.
- fluorine-based release agent examples include DAIFREE, manufactured by Daikin Industries, Ltd. and FRELEASE, manufactured by Neos Company Limited.
- silicone-based release agent examples include SPRAY 200, manufactured by Dow Corning Toray Silicone Co., Ltd.; KF96SP, manufactured by Shin-Etsu Chemical Co., Ltd.; EPOLEASE 96, manufactured by Pelnox, Ltd.; KURE-1046, manufactured by Kure Engineering Ltd.; and the like. These can be used solely or in combination of two or more kinds thereof.
- silicone-based release agents are preferred.
- Examples of a method of spraying the external release agent onto the above-described moving collecting surface include a method by spraying and the like.
- the following fiber products can be given as examples of a fiber product using the fibrous non-woven fabric of the first invention. That is, a member for a disposable diaper, a stretchable member for a diaper cover, a stretchable member for a sanitary product, a stretchable member for a hygienic product, a stretchable tape, an adhesive bandage, a stretchable member for clothing, an insulating material for clothing, a heat insulating material for clothing, a protective suit, a hat, a mask, a glove, a supporter, a stretchable bandage, a base fabric for a fomentation, a non-slip base fabric, a vibration absorber, a finger cot, an air filter for a clean room, an electret filter subjected to electret processing, a separator, a heat insulator, a coffee bag, a food packaging material, a ceiling skin material for an automobile, an acoustic insulating material, a cushioning material, a speaker dust-proof
- a spunbonded nonwoven fabric according to a second invention is constituted of fibers having a fineness of 0.2 to 1.0 denier (preferably 0.2 to 0.8 deniers, more preferably 0.2 to 0.6 deniers, and still more preferably 0.3 to 0.6 deniers).
- spunbond woven fabric according to the second invention Details of the spunbond woven fabric according to the second invention are the same as those in the fibrous nonwoven fabric according to the first invention, except that the spunbond woven fabric is not limited to one composed of the resin composition (C) containing the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B) as described above.
- the spunbond woven fabric according to the second invention can be suitably produced by the spunbond method (production condition 1) using the above-described ejector system.
- the polypropylene was subjected to press molding to fabricate a test piece, the initial elastic modulus of which was then measured by a tensile test in conformity with JIS K-7113.
- a half-crystallization time measured by the following method using FLASH DSC (manufactured by Mettler-Toledo International Inc.) was used.
- the melt flow rate was measured under conditions at a temperature of 230°C and at a load of 21.18 N in conformity with JIS K7210.
- the melting point (Tm - D) was determined from a peak top of a peak observed on the highest temperature side of a melt endothermic curve obtained by maintaining 10 mg of the sample at -10°C for 5 minutes and then increasing the temperature at a rate of 10°C/min by using a differential scanning calorimeter (DSC-7, manufactured PerkinElmer Inc.) under a nitrogen atmosphere.
- DSC-7 differential scanning calorimeter
- the weight average molecular weight (Mw) and the molecular weight distribution (Mw/Mn) were determined by a gel permeation chromatography (GPC) method. The following device and conditions were used in the measurement to obtain a weight average molecular weight as converted into polystyrene.
- the mesopentad fraction [mmmm], the racemic pentad fraction [rrrr], and the racemic-meso-racemic-meso pentad fraction [rmrm] are measured in conformity with the method proposed by A. Zambelli, et al., "Macromolecules, 6, 925 (1973)” and are a meso fraction, a racemic fraction, and a racemic-meso-racemic-meso fraction, respectively in the pentad units of the polypropylene molecular chain that are measured based on a signal of the methyl group in the 13 C-NMR spectrum.
- the mesopentad fraction [mmmm] increases, the stereoregularity increases.
- the triad fractions [mm], [rr], and [mr] were also calculated by the above-described method.
- the half-crystallization time was also measured by the above-described measuring method. Furthermore, a value obtained by dividing the half-crystallization time of the resin composition by the half-crystallization time of the high-crystalline polypropylene was defined as a relative crystallization time ratio. Results are shown in Table 2.
- the above-described resin composition was melt extruded at a resin temperature of 250°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.3 mm (hole number: 841 holes) at a rate of 0.1 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by an ejector at a pressure of 1.0 kg/cm 2 while cooling with air and laminated on a net surface moving at a line speed of 11 m/min.
- a fiber bundle laminated on the net surface was embossed at a nip pressure of 40 N/mm by using calendar rolls heated at 140°C and then wound up by a wind-up roll.
- [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.1.
- the resulting fibrous nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the following measuring methods. Measurement results are shown in Table 2.
- the weight of the resulting nonwoven fabric of 5 cm ⁇ 5 cm was measured, thereby measuring the basis weight (g/10 m 2 ).
- test piece 200 mm in length ⁇ 50 mm in width of the resulting nonwoven fabric
- sampling was conducted in the machine direction (MD) and the cross-machine direction (CD) vertical to the machine direction.
- MD machine direction
- CD cross-machine direction
- the test piece was set at an initial length L0 of 100 mm, stretched at a tensile speed of 300 mm/min, and measured for a stain and a load in the stretching process, and values of the load and the strain at the moment when the nonwoven fabric was broken were defined as breaking strength and breaking strain, respectively.
- a test piece of 100 mm in length ⁇ 100 mm in width was fabricated from the resulting nonwoven fabric, and the cantilever test was conducted by using a cantilever tester having a slope having an incline angle of 45°C in one end of a seating thereof.
- the test piece was slipped on the seating at a fixed speed in the slope direction, and a movement distance of the nonwoven fabric at the moment when the test piece was bent and one end thereof came into contact with the slope was measured.
- the measurement was conducted in both of the machine direction (MD) and the cross-machine direction (CD) vertical to the machine direction.
- Example 2 A nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the discharge amount per hole was changed to 0.2 g/min, the ejector pressure was changed to 4.0 kg/cm 2 , and the line speed was changed to 24 m/min. Results are shown in Table 2. At that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.05.
- Example 2 A nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the discharge amount per hole was changed to 0.3 g/min, the ejector pressure was changed to 2.0 kg/cm 2 , and the line speed was changed to 35 m/min. Results are shown in Table 2. At, that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.15.
- a nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the addition amount of the low-crystalline polypropylene was changed to 1% by mass, the discharge amount per hole was changed to 0.5 g/min, the ejector pressure was changed to 2.0 kg/cm 2 , and the line speed was changed to 54 m/min. Results are shown in Table 2. At that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.25.
- a nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the low-crystalline polypropylene was not added, the discharge amount per hole was changed to 0.5 g/min, the ejector pressure was changed to 2.0 kg/cm 2 , and the line speed was changed to 54 m/min. Results are shown in Table 2. At that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.25.
- the above-described resin composition was melt extruded at a resin temperature of 250°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.47 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 8,000 Pa while cooling with air and laminated on a net surface moving at a line speed of 180 m/min.
- a fiber bundle laminated on the net surface was embossed at a nip pressure of 100 N/mm by using calendar rolls heated at 140°C and then wound up by a wind-up roll.
- "[T]/[C] ⁇ 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.06.
- the resulting nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the above-described measuring methods. Measurement results are shown in Table 3.
- a nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, the cabin pressure was changed to 6,500 Pa. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.07.
- a nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, 15 parts by mass of the low-crystalline polypropylene and 85 parts by mass of the high-crystalline polypropylene B were mixed, and the erucic acid amide was not added, thereby preparing a resin composition; the cabin pressure was changed to 7,500 Pa; and the line speed was changed to 150 m/min. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.05.
- a nonwoven fabric was molded and evaluated in the same manners as those in Example 6, except that in Example 6, the cabin pressure was changed to 6,000 Pa. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.06.
- the above-described resin composition was melt extruded at a resin temperature of 245°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.40 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 5,500 Pa while cooling with air and laminated on a net surface moving at a line speed of 530 m/min.
- a fiber bundle laminated on the net surface was embossed at a nip pressure of 100 N/mm by using calendar rolls heated at 146°C and then wound up by a wind-up roll.
- "[T]/[C] ⁇ 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.07.
- the resulting nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the above-described measuring methods. Measurement results are shown in Table 3.
- the above-described resin composition was melt extruded at a resin temperature of 240°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.57 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 6,000 Pa while cooling with air and laminated on a net surface moving at a line speed of 214 m/min.
- a fiber bundle laminated on the net surface was embossed at a nip pressure of 70 N/mm by using calendar rolls heated at 136°C and then wound up by a wind-up roll.
- "[T]/[C] ⁇ 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.10.
- the resulting nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the above-described measuring methods. Measurement results are shown in Table 3.
- a nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, 1 part by mass of the low-crystalline polypropylene and 99 parts by mass of the high-crystalline polypropylene B were mixed, and the erucic acid amide was not added, thereby preparing a resin composition; the cabin pressure was changed to 4,500 Pa; and the line speed was changed to 220 m/min. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.13.
- Example 4 A nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, only the high-crystalline polypropylene B was added as the raw material resin without adding the low-crystalline polypropylene and the erucic acid amide; the cabin pressure was changed to 4,500 Pa; and the line speed was changed to 220 m/min. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.14.
- a resin composition was prepared by mixing 25 parts by mass of a low-crystalline polypropylene ("L-MODU (a registered trademark) S901", manufactured by Idemitsu Kosan Co., Ltd., MFR: 50 g/10 min, melting point: 70°C) and 75 parts by mass of the high-crystalline polypropylene C ("MOPLEN HP561S", manufactured by LyondellBasell, MFR: 33 g/10 min, melting point: 163°C) without adding erucic acid amide.
- L-MODU low-crystalline polypropylene
- S901 low-crystalline polypropylene
- MFR 50 g/10 min, melting point: 70°C
- MOPLEN HP561S manufactured by LyondellBasell
- the above-described resin composition was melt extruded at a resin temperature of 236°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.57 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 5,500 Pa while cooling with air and laminated on a net surface moving at a line speed of 215 m/min.
- a fiber bundle laminated on the net surface was embossed at a nip pressure of 90 N/mm by using calendar rolls heated at 134°C and then wound up by a wind-up roll.
- [T]/[C] ⁇ 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.10.
- the fibrous nonwoven fabric of the present invention is extremely small in fiber diameter and good in hand touch feeling and is especially preferably used for hygienic materials, such as a paper diaper, etc.
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Abstract
Description
- The present invention relates to a fibrous nonwoven fabric using a polyolefin material.
- In recent years, polyolefin-based fibers and nonwoven fabrics are used for various applications, such as a disposable diaper, a sanitary product, a hygienic product, a clothing material, a bandage, a packaging material, etc. The fibers and nonwoven fabrics are often used for applications in which they come into direct contact with the body, and thus, in recent years, a required performance regarding good wear feeling to the body and hand touch feeling are being more increased. For this reason, with respect to the nonwoven fabrics, technological development related to an improvement of texture for good wear feeling, reduction in basis weight for weight reduction of products, and the like is demanded.
- However, in producing a nonwoven fabric using a conventionally used polyolefin-based resin by a spunbond method, for the purpose of aiming to reduce fiber diameter, if a discharge amount per hole is decreased, or a spinning speed is increased, end breakage occurs frequently, so that stable spinnability is not obtained. When the end breakage occurs, the broken fiber catches up surrounding fibers to cause a roping phenomenon, or the nonwoven fabric in a part where the end breakage occurs or a part where the roped fiber falls leads to a defect or uneven basis weight, and therefore, defective quality of the nonwoven fabric is brought. For this reason, it is desired to make both stable spinnability free from the occurrence of end breakage and reducing the fiber diameter compatible with each other.
- PTL 1:
WO2011/030893 - Here, PTL 1 discloses a spunbonded nonwoven fabric using a resin composition containing a low-crystalline polypropylene and a high-crystalline polypropylene; however, from the viewpoint of providing a nonwoven fabric having more excellent flexibility and higher strength, fibers constituting the nonwoven fabric are required to more reduce fiber diameter.
- In view of the foregoing circumstances, the present invention has been made, and its object is to reduce fiber diameter of fibers constituting a fibrous nonwoven fabric using a polyolefin resin composition while preserving spinning stability.
- The present inventors made extensive and intensive investigations. As a result, it has been found that the above-described problem is solved by using a polyolefin resin composition having a specified crystallization rate.
- Specifically, the present invention provides the following.
- 1. A fibrous nonwoven fabric including a resin composition (C) containing a high-crystalline polyolefin (A) and a low-crystalline polyolefin (B), the fibrous nonwoven fabric satisfying the following conditions (1) and (2):
- (1) a half-crystallization time (ta) of the high-crystalline polyolefin (A) and a half-crystallization time (tb) of the low-crystalline polyolefin (B) satisfy a relation of ta < tb; and
- (2) a half-crystallization time (tc) of the resin composition (C) is 1.2 to 2.0 times the half-crystallization time (ta) of the high-crystalline polyolefin (A).
- 2. The fibrous nonwoven fabric according to the above item 1, wherein a fineness of fibers constituting the fibrous nonwoven fabric is 0.2 to 1.3 deniers.
- 3. The fibrous nonwoven fabric according to the above item 2, wherein the fineness of fibers constituting the fibrous nonwoven fabric is 0.2 to 0.8 deniers.
- 4. The fibrous nonwoven fabric according to any one of the above items 1 to 3, wherein an initial elastic modulus of the high-crystalline polyolefin (A) is 500 to 2,000 MPa, and an initial elastic modulus of the low-crystalline polyolefin (B) is 5 MPa or more and less than 500 MPa.
- 5. The fibrous nonwoven fabric according to any one of the above items 1 to 4, wherein when molding the fibrous nonwoven fabric, molding is performed in a discharge amount per hole of 0.1 to 0.5 g/min.
- 6. A spunbonded nonwoven fabric constituted of fibers having a fineness of 0.2 to 1.0 denier.
- According to the present invention, in a fibrous nonwoven fabric using a polyolefin resin composition, the reduction of diameter of fibers constituting the nonwoven fabric can be achieved while preserving spinning stability.
- A fibrous nonwoven fabric of a first invention is composed of a resin composition containing a high-crystalline polyolefin (A) and a low-crystalline polyolefin (B). It is to be noted that the low-crystalline polyolefin (B) as referred to in the present invention means a crystalline polyolefin having a longer half-crystallization time than the high-crystalline polyolefin (A). That is, a half-crystallization time (ta) of the high-crystalline polyolefin (A) and a half-crystallization time (tb) of the low-crystalline polyolefin (B) satisfy a relation of ta < tb.
- The high-crystalline polyolefin (A) which is used in the first invention is not particularly limited in terms of a kind thereof so long as it satisfies a condition (2) regarding a resin composition (C) as described later. Examples thereof include polyethylene, a propylene homopolymer, an ethylene-propylene copolymer, an ethylene-α-olefin copolymer, a propylene-α-olefin copolymer, an α-olefin homopolymer, a copolymer of plural α-olefins, and the like. This α-olefin is preferably one having 4 to 24 carbon atoms, more preferably one having 4 to 12 carbon atoms, and especially preferably one having 4 to 8 carbon atoms.
- As for the above-described high-crystalline polyolefin (A), its initial elastic modulus is preferably 500 to 2,000 MPa, more preferably 600 to 2,000 MPa, and still more preferably 700 to 1,800 MPa. The initial elastic modulus as referred to in this description is one measured by the following measuring method.
- A press sheet having a thickness of 1 mm was fabricated. A test piece was sampled from the resulting press sheet in conformity with JIS K7113 (2002) No. 2-1/2. Using a tensile tester (AUTOGRAPH AG-1, manufactured by Shimadzu Corporation), the test piece was set at an initial length L0 of 40 mm, stretched at a tensile speed of 100 mm/min, and measured for a strain and a load in the stretching process, and the initial elastic modulus was calculated according to the following expression.
- It is to be noted that the half-crystallization time (ta, tb, and tc) as referred to in this description means one measured by the following measuring method.
- The measurement is made using FLASH DSC (manufactured by Mettler-Toledo International Inc.) in the following method.
- (1) A sample is melted by heating at 230°C for 2 minutes and then cooled to 25°C at a rate of 2,000°C/sec, and a time change of heating value in an isothermal crystallization process at 25°C is measured.
In the conventional DSC measurement, since the above-described abrupt cooling could not be performed, crystallization started in the cooling process, so that accurate evaluation of the isothermal crystallization in the neighborhood of room temperature could not be achieved. - (2) When an integrated value of heating value from start of the isothermal crystallization to completion of the crystallization is defined as 100%, a time from start of the isothermal crystallization until the integrated value of heating value reaches 50% is defined as the half-crystallization time.
- The above-described low-crystalline polyolefin (B) is not particularly limited in terms of a kind thereof so long as it has a longer half-crystallization time than the high-crystalline polyolefin (A) as described above. Examples thereof include polyethylene, a propylene homopolymer, an ethylene-propylene copolymer, a propylene-α-olefin copolymer, an α-olefin homopolymer, a copolymer of plural α-olefins, and the like. This α-olefin is preferably one having 4 to 24 carbon atoms, more preferably one having 4 to 12 carbon atoms, and especially preferably one having 4 to 8 carbon atoms.
- As for the above-described low-crystalline polyolefin (B), its initial elastic modulus is preferably 5 MPa or more and less than 500 MPa, more preferably 10 to 400 MPa, and still more preferably 20 to 300 MPa. The initial elastic modulus of the low-crystalline polyolefin (B) can be measured in the same manner as that in the above-described high-crystalline polyolefin (A).
- In the case where the high-crystalline polyolefin (A) is a general-purpose polypropylene, the low-crystalline polyolefin (B) is preferably a low-crystalline polypropylene satisfying the following condition (a), and more preferably a low-crystalline polypropylene satisfying all of the following conditions (a) to (f).
- As for the above-described low-crystalline polypropylene, its [mmmm] (mesopentad fraction) is 20 to 60 mol%. When the [mmmm] is 20 mol% or more, solidification after melting is fast, stickiness of the fibers is suppressed, and attachment onto a wind-up roll is hardly caused, and therefore, continuous molding becomes easy. In addition, when the [mmmm] is 60 mol% or less, a degree of crystallization is lowered, and therefore, end breakage is hardly caused, and furthermore, a nonwoven fabric having a soft touch feeling is obtained. From such viewpoints, the [mmmm] of the above-described low-crystalline polypropylene is more preferably 30 to 50 mol%, and still more preferably 40 to 50 mol%.
- As for the above-described low-crystalline polypropylene, its [rrrr]/(1 - [mmmm]) is preferably 0.1 or less. The [rrrr]/(1 - [mmmm]) is an index indicating the uniformity of regularity distribution of the low-crystalline polypropylene. When this value is small, the resultant does not become a mixture of a high-stereoregular polypropylene and an atactic polypropylene, as in the conventional polypropylene which is produced using an existent catalyst system, and stickiness is hardly caused. From such a viewpoint, the [rrrr]/(1 - [mmmm]) of the above-described low-crystalline polypropylene is more preferably 0.05 or less, and still more preferably 0.04 or less.
- As for the above-described low-crystalline polypropylene, its [rmrm] (racemic-meso-racemic-meso pentad fraction) is preferably more than 2.5 mol%. If the [rmrm] is 2.5 mol% or less, random properties of the low-crystalline polypropylene are reduced, the degree of crystallization is increased due to crystallization by an isotactic polypropylene block chain, end breakage is caused, and furthermore, a soft touch feeling is not obtained in the resulting nonwoven fabric. The [rmrm] of the above-described low-crystalline polypropylene is more preferably 2.6 mol% or more, and still more preferably 2.7 mol% or more. An upper limit thereof is usually about 10 mol%.
- As for the above-described low-crystalline polypropylene, its [mm] (mesotriad fraction) × [rr] (racemic triad fraction)/[mr] (meso-racemic triad fraction)2 is preferably 2.0 or less. The [mm] × [rr]/[mr]2 indicates an index of random properties of the polymer, and when the [mm] × [rr]/[mr]2 is smaller, the random properties become higher, the frequency of end breakage is reduced, and a nonwoven fabric having a soft touch feeling is obtained. When this value is 2.0 or less, end breakage is not caused in fibers obtained by spinning, and a nonwoven fabric having a good soft touch feeling is obtained. From such a viewpoint, the [mm] × [rr]/[mr]2 of the above-described low-crystalline polypropylene is more preferably more than 0.25 and 1.8 or less, and still more preferably 0.5 to 1.5.
- As for the above-described low-crystalline polypropylene, its weight average molecular weight is preferably 10,000 to 200,000. When the weight average molecular weight is 10,000 or more, the viscosity of the low-crystalline polypropylene is not excessively low but is appropriate, and therefore, end breakage on the occasion of spinning is suppressed. In addition, when the weight average molecular weight is 200,000 or less, the viscosity of the low-crystalline polypropylene is not excessively high, and spinnability is improved. From such a viewpoint, the weight average molecular weight of the above-described low-crystalline polypropylene is more preferably 30,000 to 100,000, and still more preferably 40,000 to 80,000.
- As for the low-crystalline polypropylene which is used in the first invention, its molecular weight distribution (Mw/Mn) is preferably less than 4.0. When the molecular weight distribution is less than 4.0, the generation of stickiness in the fibers obtained by spinning is suppressed. The molecular weight distribution (Mw/Mn) of the above-described low-crystalline polypropylene is more preferably 3.0 or less, and still more preferably 2.5 or less.
- By using the low-crystalline polypropylene satisfying the above-described conditions (a) to (f) together with the above-described general-purpose polypropylene, a raw material compensating disadvantages of the general-purpose polypropylene and suitable for the production of a target nonwoven fabric is obtained.
- It is to be noted that the low-crystalline polypropylene satisfying the above-described condition (a) may also be a copolymer using other comonomer than propylene so long as it satisfies the condition (2) regarding the resin composition (C) as described later. In this case, the amount of the comonomer is usually 2% by mass or less. Examples of the comonomer include ethylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicocene, and the like. In the present invention, one or two or more kinds of these monomers can be used.
- The resin composition (C), which is a raw material of the fibrous nonwoven fabric of the first invention, contains the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B) as described above, and a half-crystallization time (tc) of the resin composition (C) is 1.2 to 2.0 times the half-crystallization time (ta) of the high-crystalline polyolefin (A).
- If the half-crystallization time (tc) is less than 1.2 times the half-crystallization time (ta), the crystallization rate of the resin composition (C) is fast, and on the occasion of melt molding of fibers, and the molten resin discharged from a nozzle is immediately crystallized, and therefore, end breakage is liable to occur, reducing the fiber diameter is difficultly achieved, and the fiber diameter is limited to 1.7 deniers or more. Meanwhile, if the half-crystallization time (tc) is more than 2.0 times the half-crystallization time (ta), the fiber surface is sticky, roping (phenomenon in which the fibers stick to each other) is generated, and stable spinning cannot be achieved. In addition, the fibers become thick due to shrinkage, so that reducing the fiber diameter cannot be achieved, too.
- From the above-described viewpoints, the half-crystallization time (tc) is preferably 1.2 to 1.9 times, and more preferably 1.3 to 1.9 times the half-crystallization time (ta).
- Examples of a method of controlling the half-crystallization time (tc) of the resin composition (C) to 1.2 times or more the half-crystallization time (ta) of the high-crystalline polyolefin (A) include a method of increasing a ratio of the low-crystalline polyolefin (B) in the combination of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B); a method of changing the low-crystalline polyolefin (B) to one having a longer half-crystalline time (tb); and the like. Meanwhile, examples of a method of controlling the half-crystallization time (tc) of the resin composition (C) to 2.0 times or less the half-crystalline time (ta) of the high-crystalline polyolefin (A) include a method of decreasing a ratio of the low-crystalline polyolefin (B) in the combination of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B); a method of changing the low-crystalline polyolefin (B) to one having a shorter half-crystalline time (tb); and the like.
- The content of the high-crystalline polyolefin (A) in the above-described resin composition (C) is not particularly limited so long as it falls within the range where the condition (2) regarding the resin composition (C) can be satisfied. In addition, the contents of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B) in order to satisfy the condition (2) regarding the resin composition (C) vary depending upon what kinds of polyolefins are selected with respect to the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B).
- As an example, in the case where the high-crystalline polyolefin (A) is a general-purpose polypropylene, and the low-crystalline polyolefin (B) is a low-crystalline polypropylene satisfying the above-described initial elastic modulus, the content of the high-crystalline polyolefin (A) in the above-described resin composition (C) is preferably 50 to 98% by mass, and more preferably 60 to 95% by mass.
- In addition, the content of the low-crystalline polyolefin (B) in the above-described resin composition (C) is preferably 2 to 50% by mass, and more preferably 5 to 40% by mass.
- Furthermore, in the above-described resin composition (C), the content of the low-crystalline polypropylene satisfying the above-described initial elastic modulus is preferably 2 to 35% by mass, any more preferably 5 to 30% by mass on the basis of a total sum of the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B).
- The above-described resin composition (C) may contain other thermoplastic resin and various additives, such as a release agent, etc. so long as it satisfies the above-described physical properties.
- Examples of the other thermoplastic resin include olefin-based polymers. Specifically, examples thereof include a polypropylene, a propylene-ethylene copolymer, a propylene-ethylene-diene copolymer, a polyethylene, an ethylene/α-olefin copolymer, an ethylene-vinyl acetate copolymer, a hydrogenated styrene-based elastomer, and the like. These may be used solely or may be used in combination of two or more kinds thereof.
- The above-described release agent refers to an additive for improving release properties such that the molded nonwoven fabric does not attach to a roll or a conveyor of a molding machine. The release agent which is contained in the resin composition (C) is called an internal release agent, and the internal release agent refers to an additive for improving release properties of the nonwoven fabric upon being added to the resin raw material. An external release agent as described later refers to an additive for improving release properties of the nonwoven fabric upon being coated directly on a roll or a conveyor of a molding machine.
- Examples of the internal release agent include organic carboxylic acids or metal salts thereof, aromatic sulfonic acid salts or metal salts thereof, organic phosphoric acid compounds or metal salts thereof, dibenzylidene sorbitol or derivatives thereof, rhodinic acid partial metal salts, inorganic fine particles, imidic acids, amide acids, quinacridones, quinones, and mixtures thereof.
- Examples of the metal in the above-described metal salt of an organic carboxylic acid include Li, Ca, Ba, Zu, Mg, Al, Pb, and the like. In addition, examples of the carboxylic acid include fatty acids, such as octylic acid, palmitic acid, lauric acid, stearic acid, behenic acid, montanic acid, 12-hydroxystearic acid, oleic acid, isostearic acid, ricinoleic acid, etc.; and aromatic acids, such as benzoic acid, p-t-b-benzoic acid, etc. Specific examples thereof include aluminum benzoate, aluminum p-t-butylbenzoate, sodium adipate, sodium thiophenecarboxylate, sodium pyrrolecarboxylate, and the like.
- Specific examples of the above-described dibenzylidene sorbitol or derivative thereof include dibenzylidene sorbitol, 1,3:2,4-bis(o-3,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-2,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-ethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-chlorobenzylidene)sorbitol, 1,3:2,4-dibenzylidene sorbitol, and the like. More specifically, GELOL MD and GELOL MD-R, all of which are manufactured by New Japan Chemical Co., Ltd., and the like are exemplified.
- Examples of the above-described rhodinic acid partial metal salt include PINECRYSTAL KM1600, PINECRYSTAL KM1500, and PINECRYSTAL KM1300, all of which are manufactured by Arakawa Chemical Industries, Ltd., and the like.
- Examples of the above-described inorganic fine particle include talc, clay, mica, asbestos, glass fiber, glass flake, glass bead, calcium silicate, montmorillonite, bentonite, graphite, aluminum powder, alumina, silica, diatomaceous earth, titanium oxide, magnesium oxide, pumice powder, pumice balloon, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite, molybdenum sulfide, and the like. In addition, synthetic silica may be used as the silica, and examples thereof include SYLYSIA, manufactured by Fuji Silysia Chemical Ltd., MIZUKASIL, manufactured by Mizusawa Industrial Chemicals, Ltd., and the like.
- Examples of the above-described amide compound include erucic acid amide, oleic acid amide, stearic acid amide, behenic acid amide, ethylene bisstearic acid amide, ethylene bisoleic acid amide, stearyl erucamide, oleyl palmitamide, adipic acid dianilide, suberic acid dianilide, and the like.
- Examples of the above-described organic phosphoric metal salt include ADEKASTAB NA-11 and ADEKASTAB NA-21, all of which are manufactured by Adeka Corporation, and the like.
- These internal release agents can be used solely or in combination of two or more kinds thereof. In the present invention, among these internal release agents, one selected from erucic acid amide, dibenzylidene sorbitol, 1,3:2,4-bis(o-3,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-2,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-ethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-chlorobenzylidene)sorbitol, and 1,3:2,4-dibenzylidene sorbitol is preferred.
- In the resin composition (C), the content of the internal release agent is preferably 10 to 10,000 ppm by mass, and more preferably 100 to 5,000 ppm by mass on the basis of the resin mixture from which the additives are eliminated. When the content of the internal release agent is 10 ppm by mass or more, the function as the release agent is revealed, whereas when it is 10,000 ppm by mass or less, a balance between the function as the release agent and the economy becomes good.
- As the additive other than the release agent, any conventionally known additives may be blended. Examples of the additive include a foaming agent, a crystal nucleating agent, a weatherability stabilizer, a UV absorber, a light stabilizer, a heat resistance stabilizer, an antistatic agent, a flame retardant, a synthetic oil, a wax, an electric property-improving agent, a slip inhibitor, an anti-blocking agent, a viscosity-controlling agent, a coloring inhibitor, a defogging agent, a lubricant, a pigment, a dye, a plasticizer, a softening agent, an age resistor, a hydrochloric acid-absorbing agent, a chlorine scavenger, an antioxidant, and an antitack agent, and the like.
- The nonwoven fabric of the first invention is one obtained by using the above-described resin composition (C) as the raw material, and preferably one produced by a spunbond method. Typically, in the spunbond method, the nonwoven fabric is produced in such a manner that a melt-kneaded resin composition is spun, stretched, and opened to form continuous long fibers, and subsequently, in a continued step, the continuous long fibers are accumulated on a moving collecting surface and entangled. In this method, a nonwoven fabric can be produced continuously, and the resulting nonwoven fabric has large strength because fibers constituting the nonwoven fabric are stretched continuous long fibers.
- As the spunbond method of producing the fibrous nonwoven fabric of the first invention, conventionally known methods can be adopted. Fibers can be produced by extruding a molten polymer, for example, from a large nozzle with several thousands of holes or a group of small nozzles having, for example, about 40 holes. After discharged from the nozzle, molten fibers are cooled by a cross-flow cooling air system, drawn away from the nozzle, and stretched by high-speed airflow. Generally, there are two kinds of air-damping methods, and the both use a venturi effect. In the first air-damping method, filaments are stretched by using a suction slot (slot stretching). This method is conducted by using the width of a nozzle or the width of a machine. In the second air-damping method, filaments are stretched through a nozzle or a suction gun. The filaments formed through the above methods are collected to form a web on a screen (wire) or a hole forming belt. Subsequently, the web passes through a compression roll and then passes between heating calendar rolls, and the web is bounded in a portion where an embossment portion on one roll includes about 10% to 40% of the area of the web, thereby forming a nonwoven fabric.
- Specific conditions for producing the fibrous nonwoven fabric by the above-described spunbond method are hereunder explained.
- In the case of producing the fibrous nonwoven fabric of the present invention by a spunbonded nonwoven fabric molding machine using an ejector system, when the fibrous nonwoven fabric is produced by using the above-described resin composition (C) by the spunbond method under the following conditions, reducing the fiber diameter can be achieved to an extent that the fiber diameter is 1.0 denier or less.
- (1) Resin temperature: 200°C to 270°C
- (2) Discharge amount per hole: 0.1 g/min to 0.5 g/min
- (3) Ejector pressure: 1.0 kg/cm2 to 4.0 kg/cm2
- (4) Suction pressure: 600 rpm to 900 rpm
- (5) Calendar temperature: 100°C to 150°C
- (6) Nip pressure: 40 kg/cm
- As for the above-described production condition 1, in reducing fiber diameter of fibers, in particular, it is preferred to set it to conditions under which relations represented by the following expressions (1-1) to (1-4) are held between the discharge amount per hole ([T] g/min) and the ejector pressure ([E] kg/cm2).
- When the [T]/[E] is 0.25 or less, the fibers of the resulting fibrous nonwoven fabric are likely to become a fine fiber with 1.3 deniers or less; when it is 0.2 or less, the above-described fibers are likely to become a fine fiber with 1.0 denier or less; when it is 0.13 or less, the above-described fibers are likely to become a fine fiber with 0.8 deniers or less; and when it is 0.1 or less, the above-described fibers are likely to become a fine fiber with 0.6 deniers or less.
- In the case of producing the fibrous nonwoven fabric of the present invention by a spunbonded nonwoven fabric molding machine using a cabin system, when the fibrous nonwoven fabric is produced by using the above-described resin composition (C) by the spunbond method under the following conditions, reducing the fiber diameter can be achieved to an extent that the fiber diameter is 1.0 denier or less.
- (1) Resin temperature: 200°C to 270°C
- (2) Discharge amount per hole: 0.3 g/min to 0.6 g/min
- (3) Cabin pressure: 4,500 Pa to 8,000 Pa
- (4) Calendar temperature: 100°C to 150°C
- (5) Nip pressure: 100 N/mm
- As for the above-described production condition 2, in reducing fiber diameter of fibers, in particular, it is preferred to set it to conditions under which relations represented by the following expressions (2-1) to (2-4) are held between the discharge amount per hole ([T] g/min) and the cabin pressure ([C] Pa).
- When the "[T]/[C] × 1,000" is 0.09 or less, the fibers of the resulting fibrous nonwoven fabric are likely to become a fine fiber with 1.3 deniers or less; when it is 0.06 or less, the above-described fibers are likely to become a fine fiber with 1.0 denier or less; and when it is 0.05 or less, the above-described fibers are likely to become a fine fiber with 0.9 deniers or less.
- In producing the fibrous nonwoven fabric of the first invention, in the case of using an external release agent, the external release agent is sprayed onto the above-described moving collecting surface. In the case where the resin composition (C) contains the internal release agent, though the external release agent may not be sprayed onto the above-described moving collecting surface, it may also be used in combination with the internal release agent from the standpoint of obtaining good release properties.
- Specific examples of the above-described external release agent include fluorine-based release agents and silicone-based release agents. Examples of the fluorine-based release agent include DAIFREE, manufactured by Daikin Industries, Ltd. and FRELEASE, manufactured by Neos Company Limited. Examples of the silicone-based release agent include SPRAY 200, manufactured by Dow Corning Toray Silicone Co., Ltd.; KF96SP, manufactured by Shin-Etsu Chemical Co., Ltd.; EPOLEASE 96, manufactured by Pelnox, Ltd.; KURE-1046, manufactured by Kure Engineering Ltd.; and the like. These can be used solely or in combination of two or more kinds thereof. In the first invention, among these external release agents, silicone-based release agents are preferred.
- Examples of a method of spraying the external release agent onto the above-described moving collecting surface include a method by spraying and the like.
- The following fiber products can be given as examples of a fiber product using the fibrous non-woven fabric of the first invention. That is, a member for a disposable diaper, a stretchable member for a diaper cover, a stretchable member for a sanitary product, a stretchable member for a hygienic product, a stretchable tape, an adhesive bandage, a stretchable member for clothing, an insulating material for clothing, a heat insulating material for clothing, a protective suit, a hat, a mask, a glove, a supporter, a stretchable bandage, a base fabric for a fomentation, a non-slip base fabric, a vibration absorber, a finger cot, an air filter for a clean room, an electret filter subjected to electret processing, a separator, a heat insulator, a coffee bag, a food packaging material, a ceiling skin material for an automobile, an acoustic insulating material, a cushioning material, a speaker dust-proof material, an air cleaner material, an insulator skin, a backing material, an adhesive non-woven fabric sheet, various members for automobiles such as a door trim, various cleaning materials such as a cleaning material for a copying machine, the facing and backing of a carpet, an agricultural beaming, a timber drain, members for shoes such as a sport shoe skin, a member for a bag, an industrial sealing material, a wiping material, a sheet, and the like can be given. The fibrous non-woven fabric of the present invention is preferably used particularly in a hygienic material such as a paper diaper.
- A spunbonded nonwoven fabric according to a second invention is constituted of fibers having a fineness of 0.2 to 1.0 denier (preferably 0.2 to 0.8 deniers, more preferably 0.2 to 0.6 deniers, and still more preferably 0.3 to 0.6 deniers).
- Details of the spunbond woven fabric according to the second invention are the same as those in the fibrous nonwoven fabric according to the first invention, except that the spunbond woven fabric is not limited to one composed of the resin composition (C) containing the high-crystalline polyolefin (A) and the low-crystalline polyolefin (B) as described above. The spunbond woven fabric according to the second invention can be suitably produced by the spunbond method (production condition 1) using the above-described ejector system.
- The following Examples are merely explained for the purpose of exemplification and are non-limitative examples.
- To a resin mixture composed of 10 parts by mass of a low-crystalline polypropylene ("L-MODU (a registered trademark) S901", manufactured by Idemitsu Kosan Co., Ltd., MFR: 50 g/10 min, melting point: 70°C) and 90 parts by mass of a high-crystalline polypropylene A ("NOVATEC SA-03", manufactured by Japan Polypropylene Corporation, MFR: 30 g/10 min, melting point: 160°C), erucic acid amide was added in an amount of 2,000 ppm on the basis of the resin mixture, thereby preparing a resin composition.
- Physical properties of the low-crystalline polypropylene and the high-crystalline polypropylene A as described above were measured by the following measuring methods. Results are shown in Table 1.
- The polypropylene was subjected to press molding to fabricate a test piece, the initial elastic modulus of which was then measured by a tensile test in conformity with JIS K-7113.
- Thickness of test piece (No. 2 dumbbell): 1 mm
- Cross-head speed: 50 mm/min
- Loadcell: 100 kg
- A half-crystallization time measured by the following method using FLASH DSC (manufactured by Mettler-Toledo International Inc.) was used.
- (1) The sample is melted by heating at 230°C for 2 minutes and then cooled to 25°C at a rate of 2,000°C/sec, and a time change of heating value in an isothermal crystallization process at 25°C is measured.
- (2) When an integrated value of heating value from start of the isothermal crystallization to completion of the crystallization is defined as 100%, a time from start of the isothermal crystallization until the integrated value of heating value reaches 50% was defined as the half-crystallization time.
- The melt flow rate was measured under conditions at a temperature of 230°C and at a load of 21.18 N in conformity with JIS K7210.
- The melting point (Tm - D) was determined from a peak top of a peak observed on the highest temperature side of a melt endothermic curve obtained by maintaining 10 mg of the sample at -10°C for 5 minutes and then increasing the temperature at a rate of 10°C/min by using a differential scanning calorimeter (DSC-7, manufactured PerkinElmer Inc.) under a nitrogen atmosphere.
- The weight average molecular weight (Mw) and the molecular weight distribution (Mw/Mn) were determined by a gel permeation chromatography (GPC) method. The following device and conditions were used in the measurement to obtain a weight average molecular weight as converted into polystyrene.
-
- Column: TOSO GMHHR-H(S)HT
- Detector: RI detector for liquid chromatography, WATERS 150C
-
- Solvent: 1,2,4-trichlorobezene
- Measurement temperature: 145°C
- Flow rate: 1.0 mL/min
- Sample concentration: 2.2 mg/mL
- Injection amount: 160 µL
- Calibration curve: Universal Calibration
- Analysis program: HT-GPC (ver. 1.0)
- The 13C-NMR spectrum was measured with the following device under the following conditions. The peak assignment followed to the method proposed by A. Zambelli, et al., "Macromolecules, 8, 687 (1975)".
- Device: 13C-NMR device, JNM-EX400 series, manufactured by JEOL, Ltd.
- Method: Proton complete decoupling method
- Concentration: 220 mg/mL
- Solvent: Mixed solvent of 1,2,4-trichlorobenzene and deuterated benzene in a ratio of 90/10 (volume ratio)
- Temperature: 130°C
- Pulse width: 45°
- Pulse repetition time: 4 seconds
- Accumulation: 10,000 times
-
- M = m/S × 100
- R = y/S × 100
- S =Pββ + Pαβ+Pαγ
- S: Signal intensity of carbon atoms in side chain methyl of all the propylene units
- Pββ: 19.8 to 22.5 ppm
- Pαβ: 18.0 to 17.5 ppm
- Pαγ: 17.5 to 17.1 ppm
- γ: Racemic pentad chain, 20.7 to 20.3 ppm
- m: Mesopentad chain, 21.7 to 22.5 ppm
- The mesopentad fraction [mmmm], the racemic pentad fraction [rrrr], and the racemic-meso-racemic-meso pentad fraction [rmrm] are measured in conformity with the method proposed by A. Zambelli, et al., "Macromolecules, 6, 925 (1973)" and are a meso fraction, a racemic fraction, and a racemic-meso-racemic-meso fraction, respectively in the pentad units of the polypropylene molecular chain that are measured based on a signal of the methyl group in the 13C-NMR spectrum. As the mesopentad fraction [mmmm] increases, the stereoregularity increases. In addition, the triad fractions [mm], [rr], and [mr] were also calculated by the above-described method.
- In addition, with respect to the above-described resin composition, the half-crystallization time was also measured by the above-described measuring method. Furthermore, a value obtained by dividing the half-crystallization time of the resin composition by the half-crystallization time of the high-crystalline polypropylene was defined as a relative crystallization time ratio. Results are shown in Table 2.
- The above-described resin composition was melt extruded at a resin temperature of 250°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.3 mm (hole number: 841 holes) at a rate of 0.1 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by an ejector at a pressure of 1.0 kg/cm2 while cooling with air and laminated on a net surface moving at a line speed of 11 m/min. A fiber bundle laminated on the net surface was embossed at a nip pressure of 40 N/mm by using calendar rolls heated at 140°C and then wound up by a wind-up roll. Here, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.1.
- The resulting fibrous nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the following measuring methods. Measurement results are shown in Table 2.
- The weight of the resulting nonwoven fabric of 5 cm × 5 cm was measured, thereby measuring the basis weight (g/10 m2).
- The fibers in the nonwoven fabric were observed with a polarizing microscope, an average value (d) of diameter of randomly selected five fibers was measured, and the fineness of the nonwoven fabric sample was calculated from the following expression [1] by using a density of the resin (ρ = 900,000 g/m3).
- From a test piece (200 mm in length × 50 mm in width) of the resulting nonwoven fabric, sampling was conducted in the machine direction (MD) and the cross-machine direction (CD) vertical to the machine direction. Using a tensile tester (AUTOGRAPH AG-1, manufactured by Shimadzu Corporation), the test piece was set at an initial length L0 of 100 mm, stretched at a tensile speed of 300 mm/min, and measured for a stain and a load in the stretching process, and values of the load and the strain at the moment when the nonwoven fabric was broken were defined as breaking strength and breaking strain, respectively.
- From test pieces (220 mm in length × 100 mm in width and 220 mm in length × 70 mm in width) of the resulting nonwoven fabric, sampling was conducted in the machine direction (MD) and the cross-machine direction (CD) vertical to the machine direction. Two sheets of the nonwoven fabrics were overlaid on a seating of a static friction coefficient measuring device (friction measuring device AN type, manufactured by Toyo Seiki Kogyo Co., Ltd.); a weight of 1,000 g was placed thereon; the seating was inclined at a rate of 2.7 degrees/min; an angle when the nonwoven fabrics slipped 10 mm was measured; and from the weight (1,000 g) of the placed weight and the angle when the nonwoven fabrics slipped 10 mm, the static friction coefficient was calculated. The smaller friction coefficient shows that the spunbonded nonwoven fabric has good hand touch feeling and texture.
- A test piece of 100 mm in length × 100 mm in width was fabricated from the resulting nonwoven fabric, and the cantilever test was conducted by using a cantilever tester having a slope having an incline angle of 45°C in one end of a seating thereof. The test piece was slipped on the seating at a fixed speed in the slope direction, and a movement distance of the nonwoven fabric at the moment when the test piece was bent and one end thereof came into contact with the slope was measured. The measurement was conducted in both of the machine direction (MD) and the cross-machine direction (CD) vertical to the machine direction.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the discharge amount per hole was changed to 0.2 g/min, the ejector pressure was changed to 4.0 kg/cm2, and the line speed was changed to 24 m/min. Results are shown in Table 2. At that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.05.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the discharge amount per hole was changed to 0.3 g/min, the ejector pressure was changed to 2.0 kg/cm2, and the line speed was changed to 35 m/min. Results are shown in Table 2. At, that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.15.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the addition amount of the low-crystalline polypropylene was changed to 1% by mass, the discharge amount per hole was changed to 0.5 g/min, the ejector pressure was changed to 2.0 kg/cm2, and the line speed was changed to 54 m/min. Results are shown in Table 2. At that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.25.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 1, except that in Example 1, the low-crystalline polypropylene was not added, the discharge amount per hole was changed to 0.5 g/min, the ejector pressure was changed to 2.0 kg/cm2, and the line speed was changed to 54 m/min. Results are shown in Table 2. At that time, [T]/[E] obtained from a relation between the discharge amount per hole and the ejector pressure was 0.25.
Table 1 Low-crystalline polypropylene High-crystalline polypropylene A High-crystalline polypropylene B High-crystalline polypropylene C Initial elastic modulus (MPa) 125 1,650 1,550 1,450 Half-crystallization time (sec) 540 0.066 0.066 0.066 MFR (g/10 min) 50 30 36 33 Melting point (°C) 70 160 161 163 Table 2 Examples Comparative Examples 1 2 3 1 2 Composition of resin High-crystalline PP-A (parts by mass) 90 90 90 99 100 Low-crystalline PP (parts by mass) 10 10 10 1 0 Erucic acid amide (ppm) 2000 2000 2000 0 0 Properties of resin Half-crystallization time (tc, sec) 0.094 0.094 0.094 0.0693 0.066 (tc/ta) 1.42 1.42 1.42 1.05 1.00 Molding conditions Resin temperature (°C) 250 250 250 250 250 Discharge amount per hole (g/min) 0.1 0.2 0.3 0.5 0.5 Ejector pressure (kg/cm2) 1 4 2 2 2 [T]/[E] 0.1 0.05 0.15 0.25 0.25 Line speed (m/min) 11 24 35 54 54 Calendar temperature (°C) 140 135 140 140 140 Nip pressure (N/mm) 40 40 40 40 40 Basis weight (g/m2) 13 13 13 13 13 Fineness (denier) 0.4 0.5 0.9 1.6 1.7 Breaking strength (N/5 cm) MD 51 84 50 46 44 Performance of nonwoven fabric CD 17 22 19 20 19 Breaking strain (%) MD 44 70 50 55 51 CD 58 77 64 67 64 Static friction coefficient MD 0.34 0.37 0.29 0.46 0.46 CD 0.44 0.46 0.35 0.57 0.56 Cantilever test (mm) MD 52 48 56 50 51 CD 26 30 45 32 33 - To a resin mixture composed of 10 parts by mass of a low-crystalline polypropylene ("L-MODU (a registered trademark) S901", manufactured by Idemitsu Kosan Co., Ltd., MFR: 50 g/10 min, melting point: 70°C) and 90 parts by mass of a high-crystalline polypropylene B ("PP3155", manufactured by ExxonMobil, MFR: 36 g/10 min, melting point: 161°C), erucic acid amide was added in an amount of 2,000 ppm on the basis of the resin mixture, thereby preparing a resin composition.
- Physical properties of the above-described high-crystalline polypropylene B were measured by the above-described measuring methods. Results are shown in Table 1.
- In addition, with respect to the above-described resin composition, its half-crystallization time was measured by the above-described measuring method. Furthermore, a value obtained by dividing the half-crystallization time of the resin composition by the half-crystallization time of the high-crystalline polypropylene was defined as a relative crystallization time ratio. Results are shown in Table 3.
- The above-described resin composition was melt extruded at a resin temperature of 250°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.47 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 8,000 Pa while cooling with air and laminated on a net surface moving at a line speed of 180 m/min. A fiber bundle laminated on the net surface was embossed at a nip pressure of 100 N/mm by using calendar rolls heated at 140°C and then wound up by a wind-up roll. Here, "[T]/[C] × 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.06.
- The resulting nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the above-described measuring methods. Measurement results are shown in Table 3.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, the cabin pressure was changed to 6,500 Pa. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.07.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, 15 parts by mass of the low-crystalline polypropylene and 85 parts by mass of the high-crystalline polypropylene B were mixed, and the erucic acid amide was not added, thereby preparing a resin composition; the cabin pressure was changed to 7,500 Pa; and the line speed was changed to 150 m/min. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.05.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 6, except that in Example 6, the cabin pressure was changed to 6,000 Pa. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.06.
- To a resin mixture composed of 5 parts by mass of a low-crystalline polypropylene ("L-MODU (a registered trademark) S901", manufactured by Idemitsu Kosan Co., Ltd., MFR: 50 g/10 min, melting point: 70°C) and 95 parts by mass of a high-crystalline polypropylene B ("PP3155", manufactured by Exxon Mobil Corporation, MFR: 36 g/10 min, melting point: 161°C), erucic acid amide was added in an amount of 2,000 ppm on the basis of the resin mixture, thereby preparing a resin composition.
- In addition, with respect to the above-described resin composition, its half-crystallization time was measured by the above-described measuring method. Furthermore, a value obtained by dividing the half-crystallization time of the resin composition by the half-crystallization time of the high-crystalline polypropylene was defined as a relative crystallization time ratio. Results are shown in Table 3.
- The above-described resin composition was melt extruded at a resin temperature of 245°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.40 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 5,500 Pa while cooling with air and laminated on a net surface moving at a line speed of 530 m/min. A fiber bundle laminated on the net surface was embossed at a nip pressure of 100 N/mm by using calendar rolls heated at 146°C and then wound up by a wind-up roll. Here, "[T]/[C] × 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.07.
- The resulting nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the above-described measuring methods. Measurement results are shown in Table 3.
- To a resin mixture composed of 20 parts by mass of a low-crystalline polypropylene ("L-MODU (a registered trademark) S901", manufactured by Idemitsu Kosan Co., Ltd., MFR: 50 g/10 min, melting point: 70°C) and 80 parts by mass of a high-crystalline polypropylene C ("MOPLEN HP561S", manufactured by LyondellBasell, MFR: 33 g/10 min, melting point: 163°C), erucic acid amide was added in an amount of 2,000 ppm on the basis of the resin mixture, thereby preparing a resin composition.
- Physical properties of the above-described high-crystalline polypropylene C were measured by the above-described measuring methods. Results are shown in Table 1.
- In addition, with respect to the above-described resin composition, its half-crystallization time was measured by the above-described measuring method. Furthermore, a value obtained by dividing the half-crystallization time of the resin composition by the half-crystallization time of the high-crystalline polypropylene was defined as a relative crystallization time ratio. Results are shown in Table 3.
- The above-described resin composition was melt extruded at a resin temperature of 240°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.57 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 6,000 Pa while cooling with air and laminated on a net surface moving at a line speed of 214 m/min. A fiber bundle laminated on the net surface was embossed at a nip pressure of 70 N/mm by using calendar rolls heated at 136°C and then wound up by a wind-up roll. Here, "[T]/[C] × 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.10.
- The resulting nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the above-described measuring methods. Measurement results are shown in Table 3.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, 1 part by mass of the low-crystalline polypropylene and 99 parts by mass of the high-crystalline polypropylene B were mixed, and the erucic acid amide was not added, thereby preparing a resin composition; the cabin pressure was changed to 4,500 Pa; and the line speed was changed to 220 m/min. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.13.
- A nonwoven fabric was molded and evaluated in the same manners as those in Example 4, except that in Example 4, only the high-crystalline polypropylene B was added as the raw material resin without adding the low-crystalline polypropylene and the erucic acid amide; the cabin pressure was changed to 4,500 Pa; and the line speed was changed to 220 m/min. Results are shown in Table 3. At that time, [T]/[C] obtained from a relation between the discharge amount per hole and the cabin pressure was 0.14.
- A resin composition was prepared by mixing 25 parts by mass of a low-crystalline polypropylene ("L-MODU (a registered trademark) S901", manufactured by Idemitsu Kosan Co., Ltd., MFR: 50 g/10 min, melting point: 70°C) and 75 parts by mass of the high-crystalline polypropylene C ("MOPLEN HP561S", manufactured by LyondellBasell, MFR: 33 g/10 min, melting point: 163°C) without adding erucic acid amide.
- In addition, with respect to the above-described resin composition, its half-crystallization time was measured by the above-described measuring method. Furthermore, a value obtained by dividing the half-crystallization time of the resin composition by the half-crystallization time of the high-crystalline polypropylene was defined as a relative crystallization time ratio. Results are shown in Table 3.
- The above-described resin composition was melt extruded at a resin temperature of 236°C by using a single-screw extruder with a gear pump, and the molten resin was spun by discharging from a nozzle having a nozzle diameter of 0.6 mm (hole number: 5,800 holes/m) at a rate of 0.57 g/min in terms of a discharge amount per hole. Fibers obtained by spinning were sucked under the nozzle by a cooling air duct at a cabin pressure of 5,500 Pa while cooling with air and laminated on a net surface moving at a line speed of 215 m/min. A fiber bundle laminated on the net surface was embossed at a nip pressure of 90 N/mm by using calendar rolls heated at 134°C and then wound up by a wind-up roll. Here, "[T]/[C] × 1,000" obtained from a relation between the discharge amount per hole and the cabin pressure was 0.10.
- The resulting nonwoven fabric was measured for basis weight, fineness, breaking strength, breaking strain and static friction coefficient of the nonwoven fabric, and also subjected to cantilever measurement in the above-described measuring methods. Measurement results are shown in Table 3.
Table 3 Examples Comparative Examples 4 5 6 7 8 9 3 4 5 Composition of resin High-crystalline PP-B (parts by mass) 90 90 85 85 95 0 99 100 0 High-crystalline PP-C (parts by mass) 0 0 0 0 0 80 0 0 75 Low-crystalline PP (parts by mass) 10 10 15 15 5 20 1 0 25 Erucic acid amide (ppm) 2000 2000 0 0 2000 2000 0 0 0 Properties of resin Half-crystallization time (tc, sec) 0.094 0.094 0.11 0.11 0.081 0.127 0.0693 0.066 0.141 (tc/ta) 1.42 1.42 1.67 1.67 1.21 1.91 1.05 1.00 2.12 Resin temperature (°C) 250 250 250 250 245 240 250 250 236 Discharge amount per hole (g/min) 0.47 0.47 0.39 0.36 0.40 0.57 0.57 0.57 0.57 Cabin pressure (MPa) 8000 6500 7500 6000 5500 6000 4500 4000 5500 Molding conditions [T]/[C] × 1,000 0.06 0.07 0.05 0.06 0.07 0.10 0.13 0.14 0.10 Line speed (m/min) 180 180 150 140 530 214 220 220 215 Calendar temperature (°C) 140 140 140 140 146 136 140 140 134 Nip pressure (N/mm) 100 100 100 100 100 70 100 100 90 Basis weight (g/m2) 15 15 15 15 13 15 15 15 15 Fineness (denier) 0.92 1.1 0.87 0.97 1.1 1.4 1.7 1.8 1.5 Breaking strength cm) strength (N/5 MD 45 45 50 49 36 22 35 32 38 Performance of nonwoven fabric CD 21 20 25 31 18 15 16 15 24 Breaking strain (%) MD 67 72 67 63 64 47 50 43 54 CD 87 79 86 79 80 59 65 50 72 friction Static friction coefficient MD 0.26 0.25 0.57 0.57 0.27 0.25 0.55 0.55 0.61 CD 0.3 0.3 0.63 0.63 0.28 0.29 0.6 0.58 0.72 Cantilever test (mm) MD 38 39 38 38 32 35 50 47 40 CD 24 23 24 24 22 24 35 33 30 - The fibrous nonwoven fabric of the present invention is extremely small in fiber diameter and good in hand touch feeling and is especially preferably used for hygienic materials, such as a paper diaper, etc.
Claims (6)
- A fibrous nonwoven fabric comprising a resin composition (C) comprising a high-crystalline polyolefin (A) and a low-crystalline polyolefin (B), the fibrous nonwoven fabric satisfying the following conditions (1) and (2):(1) a half-crystallization time (ta) of the high-crystalline polyolefin (A) and a half-crystallization time (tb) of the low-crystalline polyolefin (B) satisfy a relation of ta < tb; and(2) a half-crystallization time (tc) of the resin composition (C) is 1.2 to 2.0 times the half-crystallization time (ta) of the high-crystalline polyolefin (A).
- The fibrous nonwoven fabric according to claim 1, wherein a fineness of fibers constituting the fibrous nonwoven fabric is 0.2 to 1.3 deniers.
- The fibrous nonwoven fabric according to claim 2, wherein the fineness of fibers constituting the fibrous nonwoven fabric is 0.2 to 0.8 deniers.
- The fibrous nonwoven fabric according to any one of claims 1 to 3, wherein an initial elastic modulus of the high-crystalline polyolefin (A) is 500 to 2,000 MPa, and an initial elastic modulus of the low-crystalline polyolefin (B) is 5 MPa or more and less than 500 MPa.
- The fibrous nonwoven fabric according to any one of claims 1 to 4, wherein when molding the fibrous nonwoven fabric, molding is performed in a discharge amount per hole of 0.1 to 0.5 g/min.
- A spunbonded nonwoven fabric constituted of fibers having a fineness of 0.2 to 1.0 denier.
Applications Claiming Priority (2)
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JP2013016250 | 2013-01-30 | ||
PCT/JP2014/052164 WO2014119687A1 (en) | 2013-01-30 | 2014-01-30 | Fibrous nonwoven fabric |
Publications (3)
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EP2952617A1 true EP2952617A1 (en) | 2015-12-09 |
EP2952617A4 EP2952617A4 (en) | 2016-10-05 |
EP2952617B1 EP2952617B1 (en) | 2019-03-06 |
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EP14745725.3A Active EP2952617B1 (en) | 2013-01-30 | 2014-01-30 | Fibrous nonwoven fabric |
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US (1) | US20150368836A1 (en) |
EP (1) | EP2952617B1 (en) |
JP (1) | JP6507442B2 (en) |
CN (1) | CN104937155B (en) |
WO (1) | WO2014119687A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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EP3220964A4 (en) * | 2014-11-18 | 2018-04-25 | Kimberly-Clark Worldwide, Inc. | Soft and durable nonwoven web |
EP3660091A4 (en) * | 2017-07-24 | 2021-06-23 | Idemitsu Kosan Co., Ltd | Polypropylene-based resin composition, and fiber and nonwoven fabric using same |
Families Citing this family (10)
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JP5938149B2 (en) * | 2013-07-23 | 2016-06-22 | 宇部エクシモ株式会社 | Method for producing drawn composite fiber and drawn composite fiber |
MX2016006090A (en) | 2013-11-20 | 2016-07-21 | Kimberly Clark Co | Absorbent article containing a soft and durable backsheet. |
CN106795670A (en) | 2013-11-20 | 2017-05-31 | 金伯利-克拉克环球有限公司 | Soft and durable nonwoven composite |
RU2719524C1 (en) * | 2016-08-23 | 2020-04-21 | Одзи Холдингз Корпорейшн | Spunbonded nonwoven material, sheet and absorbent article |
JP2018145536A (en) * | 2017-03-01 | 2018-09-20 | 出光興産株式会社 | Spun-bonded non-woven fabric |
WO2018211843A1 (en) * | 2017-05-16 | 2018-11-22 | 出光興産株式会社 | Crimped fibers and nonwoven fabric |
JP2019148032A (en) | 2018-02-27 | 2019-09-05 | 出光興産株式会社 | Fiber and non-woven fabric |
JP7378419B2 (en) | 2018-11-09 | 2023-11-13 | 出光興産株式会社 | Nonwoven fabric and its manufacturing method |
CN110037520A (en) * | 2019-04-18 | 2019-07-23 | 天津市天瑞地毯有限公司 | A kind of novel cotton loop-pile carpet |
CN110820174B (en) * | 2019-11-20 | 2021-05-28 | 邯郸恒永防护洁净用品有限公司 | Electret equipment of polypropylene melt-blown non-woven fabric |
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JP3442896B2 (en) * | 1994-04-22 | 2003-09-02 | 三井化学株式会社 | Nonwoven fabric manufacturing method and apparatus |
WO2007091444A1 (en) * | 2006-02-06 | 2007-08-16 | Mitsui Chemicals, Inc. | Spun-bonded nonwoven fabric |
JP5529392B2 (en) * | 2007-06-26 | 2014-06-25 | 出光興産株式会社 | Elastic nonwoven fabric and fiber product using the same |
US9523161B2 (en) * | 2007-06-26 | 2016-12-20 | Idemitsu Kosan Co., Ltd. | Elastic nonwoven fabric, process for producing the same, and textile product comprising the elastic nonwoven fabric |
JP2009079341A (en) * | 2007-09-04 | 2009-04-16 | Idemitsu Kosan Co Ltd | Elastic nonwoven fabric, process for producing the same, and textile product |
EP2479331B1 (en) * | 2009-09-14 | 2014-12-31 | Idemitsu Kosan Co., Ltd. | Spun-bonded nonwoven fabric and fiber product |
JP5663189B2 (en) * | 2010-01-21 | 2015-02-04 | 出光興産株式会社 | Polypropylene nonwoven fabric |
AU2011217687B2 (en) * | 2010-02-22 | 2013-05-09 | Class 1 Inc. | Apparatus, systems and methods for collecting and reclaiming anaesthetic agents and for removing nitrous oxide from exhaust gases |
EP2671992B1 (en) * | 2011-02-01 | 2016-01-06 | Idemitsu Kosan Co., Ltd. | Method for producing spun-bonded nonwoven fabric and spun-bonded nonwoven fabric |
-
2014
- 2014-01-30 JP JP2014559756A patent/JP6507442B2/en active Active
- 2014-01-30 WO PCT/JP2014/052164 patent/WO2014119687A1/en active Application Filing
- 2014-01-30 EP EP14745725.3A patent/EP2952617B1/en active Active
- 2014-01-30 US US14/763,994 patent/US20150368836A1/en not_active Abandoned
- 2014-01-30 CN CN201480006510.8A patent/CN104937155B/en active Active
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See also references of WO2014119687A1 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3220964A4 (en) * | 2014-11-18 | 2018-04-25 | Kimberly-Clark Worldwide, Inc. | Soft and durable nonwoven web |
EP3660091A4 (en) * | 2017-07-24 | 2021-06-23 | Idemitsu Kosan Co., Ltd | Polypropylene-based resin composition, and fiber and nonwoven fabric using same |
Also Published As
Publication number | Publication date |
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CN104937155A (en) | 2015-09-23 |
JP6507442B2 (en) | 2019-05-08 |
JPWO2014119687A1 (en) | 2017-01-26 |
US20150368836A1 (en) | 2015-12-24 |
CN104937155B (en) | 2019-04-16 |
EP2952617B1 (en) | 2019-03-06 |
WO2014119687A1 (en) | 2014-08-07 |
EP2952617A4 (en) | 2016-10-05 |
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