JP2001159029A - Conjugate filament, method for producing the same and thermally fused article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a conjugate filament of sheath core bond type hardly losing a functional component by volatilization in melting and molding, effectively controlling bleed of the functional component added, not negatively affecting spinnability, drawability and physical properties (strength, dimensional stability, etc.), by the functional component added, being advantageous in terms of cost due to reduction in amount of the functional component added, exhibiting at its maximum excellent functionality (deodorizing properties, antimicrobial properties, etc.), which the functional component essentially has, further having durability due to long-term continuation of the functionality even in use in contact with water and to provide a method for producing the conjugate filament and to obtain a thermally fused article. SOLUTION: A polyolefin-based first resin (H) and a polyolefin-based second component (L) compounded with the functional component (A) such as a catechin, etc., and a ceramic component (C) are subjected to coextrusion molding at each melt temperature or higher than it so that the former is made into a core component X and the latter is made into a sheath component Y to provide the conjugate filament of sheath core bond type composed of the core component X and the sheath component Y.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to functionalities (deodorant properties, antimicrobial properties, etc.), spinning properties, stretchability, and physical properties (useful for various applications such as filters for air conditioners and air purifiers). The present invention relates to a core-sheath bonded type composite filament excellent in strength, dimensional stability, etc.) and economy (cost) and a method for producing the same. The invention also relates to a heat-sealed product obtained from such a composite filament.

[0002]

2. Description of the Related Art <Polypropylene filter> A polypropylene wire that is advantageous in terms of cost and has excellent characteristics such as moldability, mechanical strength, water resistance and chemical resistance as a filter to be incorporated into air conditioners and air purifiers. Filters made of articles are widely used.

It is also known to knead a synthetic antibacterial agent into polypropylene for a filter, or to carry catechins, which are tea extract components, by external attachment or internal addition.

For example, Japanese Patent Application Laid-Open No. 1-99656 discloses an antibacterial electret filter made of polypropylene fibers into which 0.1% or more of an antibacterial agent has been kneaded. However, the antibacterial agents used in the examples of this publication are
Thiabendazole is a synthetic antibacterial agent.

[0005] Japanese Patent Application Laid-Open No. 7-148407 discloses an antiviral filter in which a filter is impregnated with a virus inactivating agent containing tea extract as an active ingredient or kneaded into a filter material. The tea extract components are tea polyphenols such as catechins. The examples include (a)
Examples of tea extract components dissolved in water to form an aqueous solution and then impregnated on an electret filter. (B) Tea extract components are mixed with polypropylene, melted, formed into a film, cut, and made into a nonwoven fabric. An example is given.

[0006] Japanese Patent Application Laid-Open No. 8-266828 discloses an antivirus filter comprising a dust collecting filter and a filter to which a tea extraction component is attached. The tea extract components are tea polyphenols such as catechins. The filters impregnated with the tea extraction component include electret filters, HEPA filters, high-performance filters, medium-performance filters, and bag filters.

<Composite monofilament made of polypropylene> [0007]
Japanese Patent No. 3969 (Patent No. 1456233) discloses a composite monofilament having a high-melting polypropylene as a core component and a low-melting polyolefin as a sheath component,
There is also reference to making the monofilament a net-like material. However, there is no description about supporting an active ingredient such as an antibacterial agent. Since the required strength is obtained by the core component and the heat-fusing property is obtained by the sheath component, the monofilament can be easily formed into a net shape or a nonwoven fabric shape.

[0008]

In the case where the tea extraction component is dissolved in water to form an aqueous solution and then externally impregnated and supported on a filter, that is, in the method of adhering and supporting by impregnation, the tea extraction component is water. Due to its familiarity, the extract has poor fixation and water resistance, and when used in contact with moisture or occasionally washed with water, the tea extract, which is an adhering component, is easily lost. There is a problem that it is.

A tea extract such as catechins is internally added (kneaded) to polypropylene as a filter material.
In the method of melt molding, tea extract components such as catechins, which are originally water-soluble, are not familiar with polypropylene, which is a non-polar resin. When immersed in water or washed with water, most of the extracted components elute and the effect is drastically reduced. Even if the internal addition amount is increased in anticipation of bleeding, the elution amount upon contact with water is still large, the cost is high, and the spinnability, stretchability and strength are inevitably reduced. In addition, in this internal addition method, a considerable amount of the effective portion of the tea extract components volatilizes during melt molding, and the relatively expensive active components are inevitably reduced.

Under such a background, the present invention is intended to prevent the loss of functional components due to volatilization during melt molding.
The bleeding of the internally added functional component is effectively suppressed, and the internally added functional component exhibits spinnability, stretchability, and physical properties (strength,
Dimensional stability, etc.), and the content of the functional component can be greatly reduced, which is advantageous in terms of cost. Deodorant, antimicrobial, etc.) to the fullest extent, and even when used in contact with water, its functionality lasts for a long time, so it is durable and even comes into contact with the human body It is an object of the present invention to provide a core-sheath bonded composite filament which is highly safe even when used in a simple manner and a method for producing the same, and to provide a heat-sealed product obtained from such a composite filament. .

[0011]

The composite filament of the present invention is a core-sheath bonded type composite filament composed of a core component X and a sheath component Y, wherein the core component X is a polyolefin-based first filament. At least one functional component selected from the group consisting of catechins, saponins, tea leaf powder, tea leaf extract and tannin (acid), wherein the sheath component Y is formed of resin (H); Polyolefin-based second resin containing (A) and ceramic component (C)
(L).

The method for producing a composite filament according to the present invention is characterized in that the polyolefin-based first resin (H) and at least one selected from the group consisting of catechins, saponins, tea leaf powder, tea leaf extract and tannin (acid). A polyolefin-based second resin (L) in which various functional components (A) and a ceramic component (C) are blended, a first resin (H) is a core component X, a functional component (A) and a ceramic The second resin (L) in which the component (C) was blended was co-extruded at a temperature equal to or higher than the melting temperature of the second resin (L) to form a sheath component Y, and was composed of a core component X and a sheath component Y. The present invention is characterized in that a core-sheath bonded type composite filament is obtained.

The net-shaped heat-sealed product of the present invention comprises the above-mentioned heat-sealed composite filament knitted fabric. The non-woven heat-sealed product of the present invention comprises the above-mentioned heat-sealed composite filament.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.

<Composite Filament> The composite filament of the present invention is a core-sheath bonded type composite filament composed of a core component X and a sheath component Y. As long as it is a core-sheath type, any of a concentric core-sheath type, an eccentric core-sheath type and a multi-core sheath type may be used.

<Core Component X> In the present invention, the core component X
Is formed of a polyolefin-based first resin (H). Examples of the polyolefin-based first resin (H) include polypropylene and polyethylene. These polyethylenes and polypropylenes may be used alone or as a mixture of different grades or types in any proportion. It is often preferable that the melting point of the first resin (H) is higher than the melting point of the second resin (L), but this is not necessarily the case.

Here, the polypropylene may be not only a homopolymer of propylene but also a copolymer of propylene with an α-olefin such as ethylene or butene-1. The melt flow rate of the polypropylene (defined later in the examples) is often between 0.3 and 400, preferably between 0.5 and 200. A typical example of polypropylene is a propylene homopolymer having a melting point of, for example, 150 ° C. or higher, and a composite filament having such a high melting point polypropylene as a core component X has spinnability, stretchability,
It is particularly preferable in terms of physical properties (strength, dimensional stability) and the like.

Examples of polyethylene include low-density polyethylene, linear low-density polyethylene, and high-density polyethylene. Polyethylene may be not only a homopolymer of ethylene but also a copolymer of ethylene with α-olefin such as propylene or butene-1. The melt index of the polyethylene (defined later in the examples) is from 0.1 to 100, preferably from 0.2
It is often set to 80.

<Sheet Component Y> On the other hand, the sheath component Y is formed of a polyolefin-based second resin (L) in which a functional component (A) and a ceramic component (C) are blended. Examples of the polyolefin-based second resin (L) include polypropylene and polyethylene. These polyethylenes and polypropylenes may be used alone or as a mixture of different grades or types in any proportion.

The polypropylene may be not only a homopolymer of propylene but also a copolymer of propylene with an α-olefin such as ethylene or butene-1. The melt flow rate of the polypropylene (defined later in the examples) is often between 0.3 and 400, preferably between 0.5 and 200.

Examples of the polyethylene include low-density polyethylene, linear low-density polyethylene, and high-density polyethylene. Polyethylene may be not only a homopolymer of ethylene but also a copolymer of ethylene with α-olefin such as propylene or butene-1. The melt index of the polyethylene (defined later in the examples) is from 0.1 to 100, preferably from 0.2
It is often set to 80.

When the composite filament to be obtained is required to have a heat-fusing property, the polyolefin second resin to be used is used.
In many cases, (L) is preferably a polyolefin having a lower melting point (preferably 5 ° C. or higher) than the polyolefin-based first resin (H), for example, polyethylene, ethylene copolymer, or propylene copolymer.

The functional components (A) include catechins, saponins, tea powder, tea extract and tannin (acid).
At least one selected from the group consisting of catechins is particularly important. These are deodorant (deodorizing, odor eliminating, harmful gas component removing, etc.), antimicrobial (antibacterial, bactericidal, bacteriostatic, antifungal, antiviral, etc.) It is a component having functional properties such as allergic properties and antioxidant properties.

As the catechins, monomeric or oligomeric catechins are used (including theaflavins). A particularly important catechin used in the present invention is a tea-derived catechin preparation having an increased catechin concentration. The main components of tea catechin are epigallocatechin, epigallocatechin gallate, epicatechin, epicatechin gallate, etc., but it is not necessary to isolate it into individual components, so it contains tea catechin consisting of a mixture of these richly Preparations (particularly those containing 20% or more, preferably 25% or more) can be suitably used as they are. 30% for commercially available tea-derived catechin preparations
Product, 50% product, 60% product, 70% product, 80% product, 90%
Since there are products, etc., it is easy to obtain them. Since catechins are also contained in various plants other than tea, such as Asenyaku, catechins derived from those plants can also be used.

Among the saponins, tea saponin can be obtained by extracting a saponin-containing component from tea leaves or tea seeds using an organic solvent or water and then repeatedly purifying the extract using a means such as column chromatography. Tea saponins include steroid saponins and triterpenoid saponins, and any of them can be used for the purpose of the present invention. Saponins are a variety of plants other than tea, such as carrots, carrots, soybeans,
Saponins from such plants can also be used because they are also contained in Psycho, Amachauru, Loofah, Onji, Kikyo, Senega, Bakumondou, Mokutsu, Timo, Gossip, Licorice, Sankirai and the like.

As the tea leaf powder or tea leaf extract, tea powder or extract such as the first tea, the second tea, the third tea, the deep brown and the cover can be used.

As the tannin (acid), a commercially available purified tannic acid can be used, and an extract of a tannic acid-containing natural plant such as quintet or gallic or a semi-purified product thereof can also be used as it is.

As the ceramic component (C), although various ceramics are used, as described in detail below, a combination of silica gel obtained through hydrous silica gel, an inorganic sintering aid and an inorganic coagulant Or
A combination of ceramic particles-inorganic sintering aid-inorganic coagulant is preferably used.

As the silica gel, a silica gel obtained through a hydrous silica gel is preferably used. At this time, the pH is adjusted by mixing an aqueous solution of a silicate with an acid to form a hydrogel, and the hydrogel is washed with water to remove ions, and then dried to obtain silica gel. As the silicate, sodium silicate represented by Na ₂ O · n SiO ₂ and potassium silicate represented by K ₂ O · n SiO ₂ are used, and the former sodium silicate is particularly important. A concentrated aqueous solution of a silicate is generally called water glass, and a typical commercially available water glass has a SiO ₂ content of 22 to 3%.
8 wt%, Na ₂ O content is 5 to 19 wt%.

As the inorganic sintering aid, phosphoric acid, sulfuric acid,
Examples include polyvalent metal salts of inorganic acids such as nitric acid and carbonic acid, and fluorides and silicofluorides of alkali metals and alkaline earth (class) metals. As the polyvalent metal salt, aluminum, zinc, magnesium, calcium, manganese and the like are preferably used, and these are usually used in the form of a hydrate or hydrate dissolved in water.

As the inorganic coagulant, a sol-form or solution-form inorganic coagulant, in particular, sol-form silicic anhydride or solution-form silicate (sodium silicate or potassium silicate)
Is preferably used. The sol-form silicic anhydride includes not only ordinary colloidal silica using water as a medium, but also organosilica sol using an organic solvent such as alcohol as a medium.

Ceramic particles-inorganic sintering aid-ceramic particles in the inorganic coagulant include various clay minerals, oxides, hydroxides, composite oxides, nitrides, carbides, silicides, borides, zeolites, Examples include cristobalite, diatomaceous earth, and polyvalent metal salts of silicic acid.
Examples of the clay mineral include kaolin, pyroxene, sericite, bentonite and the like. Examples of the oxide include alumina, titania, silica, zirconia, and magnesia. As hydroxides, aluminum, zinc,
Magnesium, calcium and manganese hydroxides. An example of a composite oxide is alum. Examples of nitrides are silicon nitride, boron nitride, and the like. Examples of carbides are silicon carbide, boron carbide, and the like. Examples of polyvalent metal salts of silicic acid include aluminum salts, zinc salts, magnesium salts, calcium salts, manganese salts and the like.

In the combination of the inorganic sintering aid and the inorganic coagulant, the ratio of each component is 100 parts by weight of the solid content of the inorganic coagulant per 100 parts by weight of the solid content of the inorganic sintering aid.
Often about 300 parts by weight or more. In the combination of ceramic particles-inorganic sintering aid-inorganic coagulant, the ceramic particles are mainly used, and the inorganic sintering aid and the inorganic coagulant are used in the amounts that exert their respective functions. Parts, the amount of the inorganic sintering aid is about 0.5 to 20 parts by weight in solid content, and the amount of the inorganic coagulant is about 0.5 to 25 parts by weight in solid content.

As described above, the sheath component Y is formed of the second polyolefin resin (L) in which the functional component (A) and the ceramic component (C) are blended. In this case, the functional component (A) and the ceramic component (C) are combined with the second resin (L).
The composite particles of the functional component (A) and the ceramic component (C) may be prepared in advance, and then the composite particles may be mixed with the second resin (L). preferable.

In the case of producing the composite particles, when the ceramic component (C) is a silica gel obtained through a hydrous silica gel, the gelation before, during or after the mixing of the silicate aqueous solution with the acid is performed. It is desirable to add the functional component (A) before the completion of the reaction so that the functional component (A) is contained in the silica gel.

The ceramic component (C) is an inorganic sintering aid
In the case of combining an inorganic coagulant, it is preferable to coagulate the ceramic while containing the functional component (A). For example, the functional component (A) is mixed with an aqueous solution of aluminum phosphate as an example of an inorganic sintering aid in the form of powder or an aqueous solution or an alcohol solution, the pH is adjusted to 3 to 4, and the inorganic coagulation is performed. PH of the system by mixing colloidal silica colloid as an example of the agent
Is brought to a neutral level, agglomeration occurs. The agglomerate is transferred to a crucible or an evaporating dish and subjected to heat treatment until it is dried in a dryer or an electric furnace.

Even when the ceramic component (C) is a combination of ceramic particles, an inorganic sintering aid, and an inorganic coagulant, it is preferable to coagulate the ceramic while containing the functional component (A). For example, an aqueous solution of aluminum phosphate as an example of an inorganic sintering additive is added to ceramic particles such as aluminum silicate, alumina, titania, etc. so as to have a viscosity similar to that of a stiffening paste, followed by kneading. The functional component (A) is mixed as a powder or as an aqueous solution or an alcohol solution (or the functional component (A) is mixed with the ceramic particles and then an inorganic sintering aid is kneaded). When an aqueous solution of aluminum acid is additionally mixed, the pH is adjusted to 3 to 4, and a colloidal solution of colloidal silica as an example of an inorganic coagulant is mixed to bring the pH of the system to a neutral level, coagulation occurs. Therefore, the aggregate is transferred to a crucible or an evaporating dish and subjected to heat treatment until it is dried in a dryer or an electric furnace.

The ratio of the second resin (L), the functional component (A), and the ceramic component (C) to the sheath component Y is determined by the ratio of the second resin (L).
The total amount of the functional component (A) and the ceramic component (C) is 1 to 40 parts by weight per 100 parts by weight (preferably 2 to 40 parts by weight).
(30 parts by weight). When the total amount of the latter is too small, the intended deodorant, antimicrobial, physiological activity, antioxidant properties and other functions are not sufficiently exhibited, while the total amount of the latter is too large, Not only does the functionality not rise above a certain level, but also the negative aspects such as a decrease in the productivity of the composite filament and a decrease in the strength and hand become noticeable.

The functional component (A) and the ceramic component
In relation to (C), the ceramic component (C) 1
1 to 300 parts by weight (preferably 2 to 200 parts by weight, more preferably 3 to 300 parts by weight)
150 parts by weight). Functional ingredient (A)
When the proportion of the functional component (A) is too small, the desired functions such as deodorant, antimicrobial, physiological activity, and antioxidant properties are insufficient, and when the proportion of the functional component (A) is too large, It breaks the balance and is disadvantageous in terms of cost.

<Ratio between core component X and sheath component Y> The ratio between the core component X and the sheath component Y in the composite filament is 30:70 to 80:20, particularly 35:65 to 7 by weight.
Preferably, the ratio is 5:25. When the ratio of the sheath component Y is too small, the desired functionality is not sufficiently exhibited because the ratio of the functional component (A) is too small, and when the obtained filament is required to have thermal adhesiveness, The thermal adhesiveness becomes insufficient. On the other hand, when the ratio of the sheath component Y is too large, the ratio of the core component X becomes relatively too small.
It tends to be unsatisfactory in spinnability, stretchability, strength, dimensional stability and the like.

<Production Method of Composite Filament> The composite filament described above comprises a polyolefin-based first resin (H) and
The polyolefin second resin (L) in which the functional component (A) and the ceramic component (C) are blended, the first resin (H) is the core component X, the functional component (A) and the ceramic component ( The second resin (L) in which C) is mixed can be produced by co-extrusion molding at a temperature not lower than the respective melting temperatures so as to become the sheath component Y. Coextrusion molding can be achieved by using two extruders and discharging linearly from a composite die. In some cases, it can be formed into a net shape using a rotating die. On the second resin (L) side, a master batch with a high concentration of the material to be added was prepared in advance,
The masterbatch can be mixed with the second resin (L) and provided for molding.

On the first resin (H) side and the second resin (L) side, if necessary, antioxidants, ultraviolet absorbers, coloring agents, lubricants, antistatic agents, matting agents, flow improvers , An auxiliary agent such as a plasticizer and a flame retardant can be added internally. In particular, on the side of the second resin (L) in which the functional component (A) and the ceramic component (C) are blended, together with a stabilizer such as an antioxidant, an anti-aggregation property or a dispersibility property such as a metal soap. It is preferable to ensure that the functional component (A) and the ceramic component (C) (particularly, composite particles composed of these two components) are uniformly dispersed by blending together a molding aid effective for improvement. (A) to improve the supportability, copper salt, iron salt, calcium salt, titanium salt, aluminum salt, silver salt, tin salt,
An appropriate amount of a metal ion source such as a zinc salt, a chromium salt, and a cobalt salt may be used together.

After the coextrusion molding, stretching is often performed.
Although there is no particular limitation on the stretching ratio, if the ratio is too small, the strength tends to be insufficient depending on the application. Therefore, the stretching ratio is usually 3 times or more, especially 4 times or more. On the other hand, if the stretching ratio is too large, troubles such as delamination between the core and the sheath may easily occur. Therefore, the upper limit of the stretching ratio is generally 10%.
Up to about twice. It should be noted that stretching is not essential, since there are some applications that do not require stretching.

<Applications and Applications> The thickness of the composite filament of the present invention is arbitrary from ultra-fine denier to ultra-thick denier. From composite filaments, nets, ropes, belts,
It is also possible to obtain secondary products such as yarn, pile, cotton (cotton), woven fabric, non-woven fabric, and knitted fabric. This composite filament or its secondary product is converted to natural fibers (cotton, hemp, silk,
Wool, etc.), synthetic resin (polyester, acrylic, polypropylene, polyethylene, nylon, vinylon, polyvinylidene chloride, polyvinyl chloride, polyurethane, etc.) based fibers and monofilaments, semi-synthetic fibers (acetate, etc.), recycled fibers (rayon, etc.) It can also be used in combination with fibers such as inorganic fibers (glass fibers, carbon fibers, etc.), monofilaments or secondary products thereof.

Examples of uses of the composite filament of the present invention or its secondary product include filters (filters for air conditioners, air cleaners, vacuum cleaners, etc.), interior materials (wall sheets, floor materials, etc.), rug materials (Mats, carpets, etc.), automotive interior materials (seat cloth, ceiling materials, flooring materials), footwear materials, industrial materials, clothing materials, bedding, sanitary materials, medical supplies, daily necessities, kitchenware, toiletries, packaging materials, etc. is there.

One of the important uses is a front filter of an air conditioner or an air purifier. At this time, a monofilament is often used in the form of a net. In this case, since polypropylene is mainly used for the filter frame, the type of the polyolefin-based second resin (L) as the sheath component Y of the composite filament of the present invention and the amount of the internal additive are selected or controlled to control the heat fusion. If the monofilament is provided with the adhesive property, the monofilament and the filter frame can be thermally fused. If the monofilament is heat-sealed in advance, there is an advantage that misalignment of the net can be effectively prevented during secondary processing or practical use.

When the composite filament of the present invention is provided with a heat-fusing property, a net-shaped heat-fused product can be obtained by heat-fusing the knitted fabric of the composite filament as described above. From the composite filament, a non-woven heat-sealed product can be obtained.

[0048]

The present invention will be further described with reference to the following examples. “Parts” and “%” are expressed on a weight basis.

In the following, MI (melt index) means the weight of a sample extruded for 10 minutes under the conditions of a temperature of 190 ° C., a load of 2160 g, and an orifice hole diameter of 2.092 mm, expressed in grams. MFR (melt flow rate) refers to a temperature of 230 ° C and a load of 2160
g, the weight of the sample extruded for 10 minutes under the condition of an orifice hole diameter of 2.092 mm is expressed in g.

<Preparation of Materials> As the first resin (H) made of high-melting polypropylene, (H ₁ ): polypropylene (PP) having a melting point of 163 ° C. and an MFR of 3.1, (H ₂ ): melting point At 163 ° C. and MFR of 5.9.

(L ₁ ): polypropylene (PP) having a melting point of 163 ° C. and MFR of 3.1; (L ₂ ): a melting point of 128 ° C. And (L ₃ ): high density polyethylene (HDPE) having an MI of 16.1 was prepared.

Functional component (A) internally added to the second resin (L) side
(A ₁ ): 30% tea catechin product (epigallocatechin, epigallocatechin gallate, epicatechin and epicatechin gallate, a tea-derived catechin preparation having a total amount of about 30%), (A ₂ ): Tea saponin having a purity of 70%, (A ₃ ): green tea powder, (A ₄ ): a powder obtained by drying a hot water extract of green tea, (A ₅ ): tannic acid having a purity of 85%.

As the raw materials of the ceramic component (C) to be internally added to the second resin (L) side: (C ₁ ): silicate (water glass); (C ₂ ): aluminum phosphate and colloidal silica; -(C ₃ ): silica, aluminum phosphate and colloidal silica were prepared.

<Functional component (A)-Ceramic component (C)
Preparation of Composite Particles> Composite particles of the functional component (A) and the ceramic component (C) were produced as follows.

( ₁ ) As for the raw material (C 1) of the ceramic component (C), the functional component (A) is added to a 1N sulfuric acid solution maintained at 0 ° C., and a 1N water glass solution is separately prepared. did. Then, while vigorously stirring the 1N sulfuric acid solution containing the functional component (A), the 1N water glass solution was added dropwise over several minutes. The temperature of the reaction solution at this time was 5 to 7 ° C. The mixed solution was washed with running water for one day, then water was removed well, then finely crushed, and vacuum-dried in a drier while applying a temperature of 50 to 60 ° C. to obtain a powdery composite.

(Part 2) Of the raw materials for the ceramic component (C), (C ₂ ) was mixed with 200 parts of a 25% aqueous solution of aluminum phosphate and the functional component (A) to adjust the pH to 3 to 3.
The pH was adjusted to 4, and 130 parts of a colloidal silica colloid solution (solid content: 40%) was added and mixed to bring the pH to neutral. Since the slurry gradually aggregated, it was transferred to an evaporating dish (or crucible) while handling was possible, and was heated in a constant temperature drier or an electric furnace, and then 100 to 300
C. and dried. As a result, a hard amorphous aggregate was obtained, which was pulverized with an automatic mortar (or ball mill) and classified with a sieve to obtain a particle having a particle size of 100 to 325 mesh. Next, the particles of this aggregate were subjected to a heat treatment in a thermostatic drier or an electric furnace.

(Part 3) With respect to (C ₃ ) among the raw materials of the ceramic component (C), 400 parts of silica having an average particle size of 325 mesh under and 130 parts of the functional component (A) are dry-mixed. 25% aluminum phosphate aqueous solution 2
The mixture was kneaded harder while adding 00 parts to obtain a paste, and this paste was added to a colloidal silica colloid solution (solid content of 4 parts).
(0%) were mixed to bring the pH to neutral.
At this point, agglomeration gradually occurs, so transfer to a crucible while handling is possible, and after drying, 100-300 ° C.
To dehydrate and hydrolyze. This was pulverized.

Examples 1 to 10 The second resin (L) was obtained by the methods (1), (2) and (3) above together with a small amount of an antioxidant and an anticoagulant (dispersant). Functional component (A) Supported ceramic component
(C) was mixed, melt-extruded and pelletized. The pellet obtained in this manner is converted into a sheath component Y and the second resin.
Using the pellet of (H) as the core component X, the extruder of the sheath component Y was 230 ° C. with two extruders equipped with a composite die.
(When (L ₁ ) is used) or 205 ° C ((L ₂ ) or (L ₃ )
The core component X was co-extruded at 230 ° C. and stretched about 6 times to obtain a core component X of 300%.
A denier monofilament (composite filament) was obtained. Next, a net was produced from this monofilament, and was fixed or thermally fused to a polypropylene frame to produce a framed front filter for an air conditioner. Table 1 shows the conditions.

Comparative Examples 1 to 4 The functional component (A) was internally added to the first resin (H ₁ ), extruded at 230 ° C., and then stretched about 6 times to obtain a 300
A denier monofilament was obtained, and a filter was produced. The conditions are also shown in Table 1.

Comparative Examples 5 to 6 Co-extrusion was carried out in the same manner as in Examples 1 to 8, except that the internal addition of the ceramic component (C) to the second resin (L) was omitted. As a result, a 300-denier monofilament (composite filament) was obtained, and then a filter was produced. The conditions are also shown in Table 1.

FIGS. 1A and 1B show the composite monofilament obtained in Example 1 and Comparative Example 1 respectively.
1 shows a model cross-sectional view of the monofilament obtained in FIG.

[0062]

[Table 1]  1st resin (H) side Second resin (L) side Complex(H) (A) (L) (A) (C) Particle  Comparative Example 1 (H₁) 97 parts (A₁) 3 parts----Comparative Example 2 (H₁) 97 parts (A_Two) 3 parts----Comparative Example 3 (H₁) 93 parts (A₁) 7 copies----Comparative Example 4 (H ₁ ) 93 parts (A ₂ ) 7 parts----  Comparative Example 5 (H₁) 50 parts-(L₁) 46 parts (A₁) 4 copies-Comparative Example 6 (H ₁ ) 50 parts-(L ₂ ) 46 parts (A ₁ ) 4 parts-  Example 1 (H₁) 50 parts-(L₁) 35 parts (A₁) 3 copies (C₁) 12 parts 1 Example 2 (H₁) 50 parts-(L_Two) 35 parts (A₁) 3 copies (C₁) 12 copies 1Example 3 (H ₁ ) 50 parts-(L ₃ ) 35 parts (A ₁ ) 3 parts (C ₁ ) 12 parts Part 1  Example 4 (H₁) 50 parts-(L_Two) 35 parts (A₁) 3 copies (C_Two) Part 12 Part 2 Example 5 (H₁) 50 parts-(L_Two) 35 parts (A_Two) 3 copies (C_Two) 12 parts 2 Example 6 (H₁) 50 parts-(L_Two) 35 parts (A_Three) 3 copies (C_Two) Part 12 Part 2 Example 7 (H₁) 50 parts-(L_Three) 35 parts (A_Four) 3 copies (C_Two) 12part 2Example 8 50 parts of (H ₁ )-35 parts of (L ₃ ) ₃ parts of (A ₅ ) 12 parts of (C ₂ ) Part 2  Example 9 (H_Two) 50 parts-(L_Two) 35 parts (A₁) 3 copies (C_Three) 12 copies 3Example 10 (H ₂ ) 50 parts-(L ₃ ) 35 parts (A ₂ ) 3 parts (C ₃ ) 12 parts Part 3

<Test> The filter prepared above was immersed in water at room temperature for 3 hours, then taken out and air-dried, then immersed in water again for 3 hours, taken out and air-dried, and dried in the first water. The amount of the functional component (A) before and after the second immersion in water was analyzed by thermal analysis using a differential thermogravimetric analyzer (the temperature was raised at a rate of 5 ° C / min in an electric furnace, and the heat balance of the sample in the heating process) (Endothermic / exothermic) and the accompanying weight increase / decrease). The filters before and after washing were subjected to a deodorizing test and an antimicrobial test under the following conditions. The results are shown separately in Tables 2 and 3.

[0064] (Deodorization Test) 1 m ³ of air cleaner which can be operated from the outside into the container, set up a filter prepared above inside, wearing five cigarettes to puff machine in a container ignition When the first one burns out, shut off the smoke evacuator,
When the last cigarette burned out, the operation of the air purifier was started, and after 5 minutes and 30 minutes of the operation, the ammonia concentration was measured using a gas detector tube. The deodorization rate was determined based on how much the concentration after one minute decreased.

(Antimicrobial Test) The antimicrobial properties of each sample were examined under the following conditions. -Test item: bacterial count reduction test-Test bacterium: Staphylococcus aureus ATCC 6538P-Test method: Use the unified test method.・ Test results: Inoculation count [A] 1.0 × 10 ⁵ log A = 5.0 Unprocessed cloth count [B] 1.6 × 10 ⁷ log B = 7.2 (Standard cotton cloth is used for unprocessed cloth) log B-log A = 2.2> 1.5 (Test is valid) Change = log C-log A Change = (log B-log A)-(log C-log A)

[0066]

[Table 2]  Comparative example Example  1 2 3 4 5 6 1 2  Before washing(A) Content (%) 2.1 2.2 4.7 4.8 2.8 3.0 2.8 2.8  After immersion in water (A) Content (%) 0.3 0.3 0.7 0.6 0.2 0.2 2.7 2.7 NH_Three Deodorization rate (%) 48 48 54 53 43 43 76 76 Antibacterial bacterial count log C 6.8 6.8 6.5 6.5 7.1 7.0 3.7 3.7 Change 1.8 1.8 1.5 1.5 2.1 2.0 -1.3 -1.3Change 0.4 0.4 0.7 0.7 0.1 0.2 3.5 3.5  (Sample 0.2 g for antibacterial test)

[0067]

[Table 3]  Example  3 4 5 6 7 8 9 10  Before washing(A) Content (%) 2.8 2.8 2.8 2.7 2.8 2.6 2.8 2.8  After immersion in water (A) Content (%) 2.7 2.7 2.7 2.7 2.7 2.4 2.7 2.7 NH_Three Deodorization rate (%) 77 77 74 73 76 72 77 77 Antibacterial bacterial count log C 3.7 3.7 3.7 3.9 3.8 4.1 3.7 3.6 Change -1.3 -1.3 -1.3 -1.1 -1.2 -0.9 -1.3 -1.43.5 3.5 3.5 3.3 3.4 3.1 3.5 3.6  (Sample 0.2 g for antibacterial test)

As shown in Tables 2 and 3, it can be seen that in Comparative Examples 1 and 2 in which the content of the functional component (A) was 3 parts, the functionality after water immersion was insufficient. Also functional ingredients
It can be seen that even in Comparative Examples 3 and 4 in which the internal addition amount of (A) is 7 parts, the functionality after water immersion is still insufficient. In Comparative Examples 5 and 6 as composite filaments,
Since the functional component (A) is internally added to the sheath component Y side, which is the outer layer, the functionality after immersion in water is even more insufficient. In addition, the first resin without the functional component (A) added internally
The NH ₃ deodorization rate when a monofilament stretched product of only (H ₁ ) and (H ₂ ) was used was about 40%, and “measured value−40%”
Is a substantial deodorization rate. In Comparative Examples (in particular, Comparative Examples 1 to 5 in which melt extrusion was performed at 230 ° C.), since the ceramic component (C) was not present, a considerable amount of the functional component (A) was volatilized during extrusion molding. You can see that there is.

<Antiviral test> Examples 1, 4, 5,
9, the first resin (H ₁ ) and the second filament
1: 1 composite filament (Contr) in weight ratio with resin (L ₁ )
ol) using a filter (3 cm
× 3 cm) was prepared, and 0.2 ml of the influenza virus suspension was added dropwise to the specimen and stored at 25 ° C. After 24 hours of storage, the virus on the sample is washed out, and the virus infectivity (50% tissue culture infectious dose per 1 ml (TCID)
The logarithmic value of ₅₀ ) was measured. Table 4 shows the results.

[0070]

[Table 4]

[0071]

According to the composite filament of the present invention,
The required spinnability, stretchability and physical properties (strength and dimensional stability) are mainly obtained by the core component X, and the functions such as deodorant, antimicrobial, physiological activity, and antioxidant are obtained by the sheath Y. . If the type of the second resin (L) and the amount of the internal additive are selected or controlled, a preferable heat-fusing property can be obtained.

And, in the sheath component Y, the functional component
(A) coexists with the ceramic component (C) and is fixed and waterproofed, so the functional component (A) is less likely to be lost due to volatilization during melt molding, and the internally added functional component The bleed of (A) is effectively suppressed. The functional component (A) present in the sheath component Y maximizes the inherent functions of the component, such as deodorant properties and antimicrobial properties. In addition, even if it is used in contact with water or washed with water, the functional component (A) does not easily elute, so that its functionality is maintained for a long time. The presence of the ceramic component (C) also contributes to improving the dimensional stability and heat resistance of the filament against environmental changes such as changes in temperature and humidity.

Further, since only the functional component (A) needs to be present in the sheath component Y on the surface side, the internal addition amount of the functional component (A) can be greatly reduced, which is economically advantageous.

In addition, since the functional component (A) is a component contained in tea or the like, it is safe to use it in contact with the human body.

[Brief description of the drawings]

FIG. 1 is a model sectional view of a composite monofilament obtained in Example 1 and a monofilament obtained in Comparative Example 1.

[Explanation of symbols]

X: core component, (H): first resin, Y: sheath component, (L): second resin, (A): functional component, (C): ceramic component

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Tetsuo Kanakawa 1-5-8 Kosakahonmachi, Toyota City, Aichi Prefecture City Heights 1001 (72) Inventor Masataka Sano 4083-1 Oyamacho, Hamamatsu City, Shizuoka Prefecture (72) Inventor Miyamatsu Hiroki 631 Terashima-cho, Hamamatsu-shi, Shizuoka (72) Inventor Takami Yoshida 536, Ryuzenji-cho, Hamamatsu-shi, Shizuoka (72) Inventor Nobuo Goto 649-17 Minamiiwasaki, Ichihara-shi, Chiba (72) Akira Yamanaka, inventor 1402-5 Harimata-cho, Moriyama-shi, Japan (72) Inventor Tomio Yamazawa 13-13, Shirahama-cho, Minamata-shi, Kumamoto (72) Inventor Takahiro Sugimoto 2-17, Tatsumidaihigashi, Ichihara-shi, Chiba

Claims (9)

[Claims] A core-sheath bonded type composite filament comprising a core component X and a sheath component Y, wherein the core component X is formed of a polyolefin-based first resin (H), And wherein the sheath component Y is a catechin, a saponin, a tea powder,
At least one functional component (A) selected from the group consisting of tea leaf extract and tannin (acid) and a ceramic component
(C) and a polyolefin-based second resin (L) mixed therewith. (2) The sheath component (Y) is formed of a polyolefin-based second resin (L) in which the functional component (A) and the ceramic component (C) are compounded in the form of a composite of the two. The composite filament according to claim 1, characterized in that: 3. The composite filament according to claim 1, wherein the melting point of the first resin (H) is higher than the melting point of the second resin (L). 4. The weight ratio of the core component X to the sheath component Y is 30: 7.
The composite filament according to claim 1, wherein the ratio is 0 to 80:20. 5. A ceramic (C) comprising silica gel obtained through hydrated silica gel, a combination of an inorganic sintering aid and an inorganic coagulant, or a ceramic particle-inorganic sintering aid-an inorganic coagulant. The composite filament according to claim 1, which is a combination. 6. The composite filament according to claim 1, which is a monofilament for a filter. 7. A functional component (A) selected from the group consisting of a polyolefin-based first resin (H) and catechins, saponins, tea leaf powder, tea leaf extract and tannin (acid). A second resin (L) of a polyolefin blended with a ceramic component (C), a first resin (H) blended with a core component X, and a functional component (A) blended with a ceramic component (C). The second resin (L) is co-extruded at a temperature equal to or higher than its melting temperature so as to become a sheath component Y, and a core-sheath bonded type composite filament composed of a core component X and a sheath component Y is formed. A method for producing a composite filament, comprising: 8. A net-shaped heat-sealed product comprising a heat-sealed product of the composite filament knitted fabric according to claim 1. 9. A non-woven heat-sealed article comprising the heat-sealed composite filament of claim 1.