JP2005023509A - Filament nonwoven fabric and process for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a filament nonwoven fabric having a moderate texture, excellent in breaking strength, suitable for clothes. <P>SOLUTION: The filament nonwoven fabric has 0.001-1.0 dtex of single filament fineness, 0.1-8×10<SP>-3</SP>Ncm<SP>2</SP>/cm of flexural rigidity measured by a KES-FB2 system, 0.1-15×10<SP>-3</SP>Ncm/cm of bending hysteresis, 10-200 N/cm of tensile strength, and 50-400 g/m<SP>2</SP>of basis weight. The method for producing the filament nonwoven fabric comprises subjecting a filament nonwoven fabric composed of splittable conjugated filaments comprising at least two components, to a water jet punching until the the fabric has 0.2-0.6 g/cm<SP>3</SP>of apparent density, and then eliminating at least one component of the splittable conjugated filaments. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  TECHNICAL FIELD The present invention relates to a long-fiber nonwoven fabric having a softness and excellent resilience, and particularly suitable for clothing, and a method for producing the same.

  Nonwoven fabrics are widely used by making use of the unique characteristics of nonwoven fabrics for clothing such as general outerwear and surgical clothes, as well as industrial materials, civil engineering, horticulture, living materials, and sanitary materials. Among them, the long fiber nonwoven fabric has a high tensile strength compared to the short fiber nonwoven fabric and has an advantage of excellent productivity because of a short manufacturing process. On the other hand, since it lacks flexibility, it was mainly used for industrial materials rather than clothing.

Then, the long fiber nonwoven fabric whose bending rigidity by KES method is 0.98 * 10 < ^-3 > Ncm < ² > / cm or less is disclosed as a long fiber nonwoven fabric excellent in the softness | flexibility (for example, refer patent document 1). However, for example, when used for apparel, it is not only necessary to be flexible, but an appropriate texture and tensile strength are required. In addition, in order to soften a long-fiber non-woven fabric composed of ordinary fineness to this range, means such as lowering the density of the non-woven fabric and cutting the fibers are necessary, lacking in solidity, and tensile strength. There is a problem that decreases.

Further, the basis weight is 10 to 50 g / m ² , the average value of bending rigidity is 0.3 × 10 ⁻³ Ncm ² / cm or less, and the average value of bending return is 2 cm ⁻¹ or less. A 5-6 dtex long fiber nonwoven fabric is disclosed (for example, see Patent Document 2). According to this, it has been shown that an appropriate texture can be obtained by imparting return resilience as well as flexibility, but the use of the nonwoven fabric is also limited because the tensile strength of the obtained nonwoven fabric is low.

  On the other hand, various methods using ultrafine fibers for the long fiber nonwoven fabric have been studied. For example, a non-woven fabric composed of splittable composite fibers is active against mechanical means such as needle punching or high pressure water flow treatment, thermal means such as water vapor, boiling water, microwaves, or at least one component of the composite fibers. Disclosed is a method of ultrafine processing by applying chemical means such as treatment with a chemical swelling agent, means for peeling off the divided components under high pressure of the heating roller using a multi-stage heating roller (for example, patents) Reference 3-6).

By these methods, it becomes possible to obtain a long-fiber nonwoven fabric composed of ultrafine fibers, although there is a description that it can be used for various uses such as artificial leather and synthetic leather base fabrics, clothing, filters, wipers, etc. None disclose the optimal configuration.
JP 2001-11767 A JP 2001-146671 A Japanese Patent Publication No. 1-44755 Japanese Patent Publication No. 1-44756 JP-A-3-213555 JP-A-10-53948

  In view of the background of such prior art, the present invention is intended to provide a long-fiber nonwoven fabric having an appropriate texture and excellent tensile strength, and particularly suitable for clothing.

In order to solve the above problems, the present invention employs the following means. That is, the long fiber nonwoven fabric of the present invention has a single fiber fineness of 0.001 to 1.0 dtex, and a bending stiffness measured by the KES-FB2 system of 0.1 to 8 × 10 ⁻³ Ncm ² /. cm, bending hysteresis is 0.1 to 15 × 10 ⁻³ Ncm / cm, tensile strength is 10 to 200 N / cm, and basis weight is 50 to 400 g / m ² .

Further, the method of manufacturing long-fiber nonwoven fabric of the present invention, the long-fiber nonwoven fabric made of splittable conjugated filaments of polymers of at least two components, subjected water jet punch, the scope of the apparent density 0.2 to 0.6 g / cm ³ Then, at least one component of the split-type composite continuous fiber is removed.

  By this invention, it can be set as the long-fiber nonwoven fabric provided with the softness | flexibility, tensile strength, and suitable texture, and can also provide for the use of the clothing which was not fully utilized until now.

  The long fiber nonwoven fabric of the present invention is required to have a single fiber fineness of 0.001 to 1.0 dtex, preferably 0.01 to 0.5 dtex, more preferably 0.04 to 0.2 dtex. It is. It is not necessary for all the constituent fibers to be in this fineness range, and other finenesses may be included as long as the effects of the present invention are not impaired, but preferably 50% or more of the total fibers observed in photography. More preferably, 80% or more is constituted by the single fiber fineness within this range. In particular, it is preferable that the single fiber fineness of at least the surface portion falls within the scope of the present invention. If it is composed of fibers of less than 0.001 decitex, the texture becomes too soft, and the surface tends to be fibrillated, and the tensile strength, abrasion resistance, color developability and the like tend to decrease, which is not preferable. Moreover, when it is comprised from the fiber exceeding 1.0 dtex, when it is set as a long-fiber nonwoven fabric, it will become difficult to make the softness | flexibility and tensile strength which are the effects of this invention compatible.

  A method for producing a so-called ultrafine fiber having a fineness in this range is not particularly limited. For example, a method of spinning directly from a die, spinning an ordinary fineness fiber with a sea-island type or split type composite fiber, and the like, And a method of making the fibers finer by treating them with a chemical or solvent capable of dissolving and / or decomposing fibers having a normal fineness. Among these, from the viewpoint of excellent spinning stability and productivity, a method of spinning a split composite fiber and then splitting it to obtain ultrafine fibers is preferable.

  Examples of the split type composite fibers include composite fibers composed of two or more components. The number of components is not particularly limited, but it is preferably 2 to 3 components in consideration of spinning stability. In addition, the component ratio is preferably 7: 3 to 3: 7, more preferably 6: 4 to 4: 6, from the viewpoint of excellent spinning stability and splitting properties in the case of two components. The components to be used are not particularly limited as long as they are combinations that can be composite-spun, but those that are not compatible with each other are preferably selected from the viewpoint of excellent splitting properties. What is not compatible is what does not substantially dissolve even when melt kneaded. For example, when one component is a polyester component, the other is polyamide, polypropylene, polyethylene, polystyrene, polyurethane component, etc. You can choose from. Among these, a combination using two components of a polyester-based component and a polyamide-based component that are particularly excellent in economic efficiency and spinning stability is preferable.

  The polyester component is not particularly limited as long as it is a polymer synthesized from dicarboxylic acid or its ester-forming derivative and diol or its ester-forming derivative and can be used as a composite fiber. .

  Specifically, for example, polyethylene terephthalate, polytrimethylene terephthalate, polytetramethylene terephthalate, polycyclohexylene dimethylene terephthalate, polyethylene-2,6-naphthalenedicarboxylate, polyethylene-1,2-bis (2- Chlorophenoxy) ethane-4,4′-dicarboxylate and the like. In the present invention, polyethylene terephthalate, which is most commonly used, or a polyester copolymer mainly containing ethylene terephthalate units is preferably used.

  In addition to diethylene glycol, these polyesters include dicarboxylic acids such as adipic acid, isophthalic acid, sebacic acid, phthalic acid, naphthalenedicarboxylic acid, 4,4′-diphenyldicarboxylic acid, and cyclohexanedicarboxylic acid, and esters thereof. Formable derivatives, dioxy compounds such as polyethylene glycol, hexamethylene glycol, neopentyl glycol, polypropylene glycol and cyclohexanedimethanol, oxycarboxylic acids such as p- (β-oxyethoxy) benzoic acid and ester-forming derivatives thereof It may be polymerized.

  Examples of the polyamide-based component include polymers having an amide bond such as nylon 6, nylon 66, nylon 610, nylon 12, and the like.

  To these polymers, inorganic particles such as titanium oxide particles may be added to the polymer in order to improve the concealing property. In addition, lubricants, pigments, heat stabilizers, ultraviolet absorbers, conductive agents, heat storages, etc. Materials, antibacterial agents, etc. can be added according to various purposes.

  The split composite fiber is not particularly limited as long as it is divided into a plurality of sections in the fiber cross section, and the outer shape may be any of a circle, an ellipse, a triangle, a square, etc., but has excellent spinning stability. It is preferable that the outer shape is a circle or an ellipse. As schematic cross-sectional examples preferably used in the present invention, schematic model diagrams are shown in FIGS. In terms of excellent splitting property, a more preferable cross section in the present invention is a shape having a hollow portion as shown in FIG. The hollow ratio is preferably 0.5 to 40%. The lower the hollow ratio, the lower the splitting property. Therefore, it is preferably 0.5% or more, and more preferably 3% or more. Further, if the hollow ratio is too high, the spinning stability is lowered, so that it is preferably 40% or less, more preferably 20% or less. Here, the hollow ratio is the area of the hollow portion relative to the cross-sectional area of the fiber.

  Also, the number of divisions is not particularly limited, but the total number after division is preferably in the range of 4 to 48, more preferably 8 to 36, in terms of excellent productivity and spinning stability.

  The die for producing the split type composite fiber is not particularly limited. For example, Japanese Patent Publication No. 39-29636, Japanese Patent Laid-Open No. 50-5650, Japanese Patent Publication No. 53-10169, Japanese Patent Publication No. A base similar to the spinneret described in Japanese Patent Application Publication No. 54-125719 can be used.

  The fiber obtained by spinning can be wound once and then opened to make a long-fiber nonwoven fabric. However, in view of excellent productivity, stretching and web formation are continuously performed without winding. It is preferable to use a long fiber nonwoven fabric.

  The base to be used is known to be round or rectangular because of its shape, but is preferably rectangular in consideration of productivity and quality, and particularly uniformity of the obtained sheet. Next, the composite polymer spun by the die is preferably stretched at a spinning speed of 3000 to 9000 m / min by an ejector, an air soccer, a roller or the like. In the present invention, a method of stretching using the above-described rectangular base and further using a rectangular ejector is preferable. After extending | stretching in this way, it collects on collection surfaces, such as a web conveyor, and makes it a web. Air suction may be performed from below the collection surface. In this case, other fibers and non-woven fabrics may be laminated, mixed, and blended as long as the effects of the present invention are not impaired.

  The web thus obtained can be subjected to a thermocompression treatment or the like with a calendar, embossing, or the like, if necessary. The conditions such as the pressure and temperature of the roll at this time are not particularly limited, and can be set as appropriate. However, although the tensile strength can be improved, the flexibility may be lowered, and therefore it is preferable that the long fiber nonwoven fabric of the present invention is not substantially thermally bonded. “Not substantially thermally bonded” means that when the surface is observed at least by photography, the area of the bonded portion due to fiber melting is 10% or less, preferably 5% or less, more preferably 1% or less. Say. In the present invention, it is preferable that the long-fiber nonwoven fabric is not substantially thermally bonded, since it has flexibility, and the manufacturing method is not particularly limited. Therefore, it is possible to manufacture by removing the bonded portion after performing the thermal bonding, but it is disadvantageous and difficult to remove the thermal bonding portion. It is preferable not to perform or to reduce the bonding area as much as possible. That is, if the thermocompression treatment is performed under the condition that the fibers are sufficiently thermally bonded, the flexibility is lowered, and it is difficult to obtain sufficient flexibility even if a stagnation treatment, a needle punch, a water jet punch, or the like is subsequently applied. . Accordingly, the thermocompression treatment is preferably carried out below the melting point of the fiber used. In the present invention, as a means for obtaining a long-fiber nonwoven fabric in the range of the bending rigidity of the present invention, it is one of preferable production methods not to perform thermal bonding.

  Next, in the present invention, it is preferable to entangle the nonwoven fabric three-dimensionally in order to impart flexibility and / or improve tensile strength. This method is not particularly limited, and for example, a needle punching method in which punching is performed with a needle with a verb and / or a water jet punching method using a high-pressure fluid, particularly a high-pressure water stream, can be used alone or in combination. In the present invention, when a split-type conjugate fiber is used, as will be described later, since it can also serve as a splitting process, the water jet punch method is preferably used. Also, in order to achieve both flexibility and tensile strength, which are the effects of the present invention, the needle punch method tends to decrease the tensile strength, so the water jet punch method is preferred.

  When water jet punching is performed, it is preferable to perform the water in a columnar flow state. In order to obtain a columnar flow, it is usually obtained by ejecting from pores having a diameter of 0.06 to 1.0 mm at a pressure of 1 to 30 MPa. Such treatment is preferably repeated many times for the purpose of achieving uniform entanglement in the thickness direction and / or improving the smoothness of the nonwoven fabric surface. Further, the water flow pressure is appropriately selected according to the basis weight of the nonwoven fabric to be treated, and the higher the basis weight, the higher the pressure. Furthermore, when using a split-type conjugate fiber, it is preferable to process at least once with a pressure of 10 MPa or more, and more preferably 15 MPa or more, for the purpose of improving splittability. Further, the upper limit is not particularly limited, but the cost increases as the pressure increases, and if the basis weight is low, the water flow penetrates to the back and the nonwoven fabric becomes non-uniform, so that it is preferably 30 MPa or less, more preferably 25 MPa. It is. Further, the water immersion process can be performed before the water jet punching.

  When a composite fiber is used, it is necessary to make it ultrafine at any stage after spinning. As the method, either a mechanical method or a chemical method can be used alone or in combination. Here, the mechanical method is a method of dividing by applying a physical stimulus, for example, a method of applying pressure between rollers in addition to a method of giving an impact such as the needle punch method or the water jet method described above, Examples include a method of performing ultrasonic treatment. The chemical method includes, for example, a method in which at least one component constituting the composite fiber is subjected to changes such as swelling, decomposition, and dissolution by a drug. In the present invention, the above-described water jet punch method is particularly preferably employed in that it can be performed in the same step as the entanglement and the balance between tensile strength and flexibility is relatively easy. This division process may be performed in-line after collection, or after temporarily setting the web, it may be wound up and processed again. Moreover, you may use a chemical process together before and after a water jet punch for the purpose of fully dividing | segmenting a composite fiber as needed.

  Furthermore, in the present invention, after these entanglement and ultrafine processing, and / or at the same time, it is preferable to perform a weight reduction process for removing at least one component for the purpose of adjusting bending rigidity and bending hysteresis. For example, in the case of a long-fiber nonwoven fabric made of polyester fiber, a treatment of hydrolyzing the fiber by using an alkaline aqueous solution such as sodium hydroxide, potassium hydroxide, lithium hydroxide or the like as necessary can be mentioned. Moreover, the dissolution removal rate at this time is not particularly limited, but is preferably 10 to 60%, more preferably 20 to 50%, based on the total weight. If it is less than 10%, the effect of removal is not remarkable, and if it exceeds 60%, the tensile strength and the like are lowered, which is not preferable.

In this weight reduction treatment, the apparent density is reduced by the removal, so the apparent density is preferably 0.2 to 0.6 g / cm ³ , more preferably 0.22 to 0.5 g with a water jet punch before the treatment. / Cm ³ . When the apparent density before the weight reduction treatment is less than 0.2 g / cm ³ , many fluffs are generated on the nonwoven fabric surface due to the weight reduction treatment, making it difficult to handle and reducing the surface quality, which is not preferable. On the other hand, if it exceeds 0.6 g / cm ³ , the resulting effect is not so great, but the processing cost by the water jet punch is increased, which is not preferable. In order to adjust to these apparent densities, it can carry out by adjusting the pressure of a water jet punch according to the apparent density and fabric weight of the nonwoven fabric. Although the apparent density can be increased by pressing or the like, it is not preferable because it is difficult to obtain the effect expected in the present invention. However, after adjusting the apparent density within the above range by the water jet punch, it is possible to further increase the apparent density by pressing. At this time, as a result of using the press together, the apparent density may be exceeded.

  The apparent density was measured according to JIS L1096 8.4.2 (1999), then the thickness was measured, and the average value of the density obtained therefrom was used as the apparent density. The thickness was measured using a dial thickness gauge (manufactured by Ozaki Mfg. Co., Ltd., trade name “Peacock H”), 10 samples were measured, and the average value was used.

  Further, in order to obtain a desired texture, it is possible to perform a stagnation treatment, and it is also possible to perform dyeing like a normal woven or knitted fabric. In particular, when used for clothing or clothing materials, it is preferable to dye at least one component because the appearance is excellent and the commercial value can be increased. The dyeing method is not particularly limited, and a dyeing method suitable for the component can be adopted. Specifically, for example, disperse dyes and cationic dyes for polyester fibers, and acid dyes and metal complex dyes for polyamide fibers. It can be dyed with reactive dyes. In the case of a long-fiber nonwoven fabric composed of two or more components, only one component may be dyed, or two or more components may be dyed. When giving priority to cost, it is preferable to dye only one component, and when giving priority to appearance, it is preferable to dye two or more components, particularly all the constituent fibers. For example, in a long-fiber nonwoven fabric composed of a polyester component and a polyamide component preferably used in the present invention, it is preferable to dye the polyamide component when only one component is dyed. In particular, when dyeing while giving a stagnation action using a liquid dyeing machine, a flexible texture can be obtained while maintaining the tensile strength. This dyeing method is very difficult when the nonwoven fabric has low entanglement, because the shape of the nonwoven fabric collapses. However, the long fiber nonwoven fabric of the present invention is excellent in entanglement, and this can be performed.

The long-fiber nonwoven fabric of the present invention needs to have a flexural rigidity of 0.1 to 8 × 10 ⁻³ Ncm ² / cm in the KES-FB2 system, preferably 0.2 to 6 × 10 ⁻³ Nc ^2. / Cm, more preferably 0.2 to 2 × 10 ⁻³ Ncm ² / cm, and still more preferably 0.2 to 1.0 × 10 ⁻³ Ncm ² / cm. If the bending rigidity is less than 0.1 × 10 ⁻³ Ncm ² / cm, it becomes too soft and difficult to handle, and it becomes difficult to balance the tensile strength. On the other hand, if it exceeds 8 × 10 ⁻³ Ncm ² / cm, it is too hard to obtain the desired texture.

Furthermore, the long-fiber nonwoven fabric of the present invention is required to have a bending hysteresis of 0.1 to 15 × 10 ⁻³ Ncm / cm, preferably 0.2 to 5 × 10 ⁻³ Ncm in the KES-FB2 system. / cm, more preferably in a range 0.2~2 × ¹⁰ -3 Ncm / cm, further preferably 0.2~1 × ¹⁰ -3 Ncm / cm. A bending hysteresis exceeding 15 × 10 ⁻³ Ncm / cm is not preferable because it tends to be deformed. On the other hand, if the bending hysteresis is less than 0.1 × 10 ⁻³ Ncm / cm, the tensile strength decreases and it becomes difficult to balance.

  Here, the value obtained with the KES-FB2 system is a value obtained with a pure bending tester manufactured by Kato Tech Co., Ltd., and arbitrarily sampled at three locations to measure the vertical and horizontal directions. Average values were used. Further, the torque sensitivity (SENS) at this time was set to “2 × 1” (standard), and measurement was performed under the conditions of 25 ° C. and humidity 60%.

  Although the manufacturing method for making the bending rigidity and bending hysteresis of a long-fiber nonwoven fabric into the range of this invention is not specifically limited, Preferably it can manufacture with the above-mentioned manufacturing method. In particular, in the present invention, it is necessary to adopt means capable of adjusting bending rigidity and bending hysteresis while maintaining the tensile strength shown below, and the manufacturing method described above is preferable from this viewpoint. Furthermore, it can be adjusted within the scope of the present invention by the fineness of the fiber to be used, the presence or absence of thermal bonding, water jet punch conditions, weight loss processing, dyeing processing, kneading processing, and the like. These adjustments differ depending on the basis weight of the target nonwoven fabric, and since various elements are related to each other, it is difficult to uniquely determine the conditions, but for example, as the single fiber fineness is reduced, The bending rigidity can be reduced, and by reducing the pressure of the water jet punch, the splitting ability can be reduced, and the bending rigidity and bending hysteresis can be increased. Furthermore, the method of adjusting bending rigidity and bending hysteresis by the above-described weight loss treatment is preferable as a means for producing the long fiber nonwoven fabric of the present invention. For example, the method of alkali-treating the long fiber nonwoven fabric using a polyester fiber is mentioned. Thereby, moderate voids are formed in the nonwoven fabric, and these values can be reduced.

Moreover, the long-fiber nonwoven fabric of the present invention needs to have a basis weight of 50 to 400 g / m ² , preferably 60 to 300 g / m ² , more preferably 70 to 200 g / m ² . If it is less than 50 g / m ^{2, although} it is excellent in flexibility, it becomes difficult to obtain a sufficient tensile strength, or it becomes difficult to achieve a balance such as a decrease in flexibility in order to obtain a sufficient tensile strength. . ^{On the other hand} , if it exceeds 400 g / m ² , high tensile strength can be easily obtained, but it is necessary to perform more softening treatment for satisfying bending rigidity and bending hysteresis, which is not preferable because the cost becomes high.

  The basis weight was determined according to JIS L1096 8.4.2 (1999).

At this time, although the apparent density of the long-fiber nonwoven fabric of the present invention is not particularly limited, preferably 0.2-0.5 g / cm ^3, more preferably 0.2-0.4 g / cm ^3, more preferably 0. 2 to 0.3 g / cm ³ . If it is less than 0.2 g / cm ³ , the sense of fulfillment will be poor, and if it exceeds 0.5 g / cm ³ , it will become stiff and it will be difficult to obtain the desired texture of the present invention. Here, the apparent density is a value obtained by simply calculating the weight per unit volume. Although the method of making this range is not specifically limited, For example, in the above-mentioned manufacturing method, it can adjust with the pressure of a water jet punch, press conditions, the presence or absence of a weight reduction process, etc.

  Furthermore, the long-fiber nonwoven fabric of the present invention needs to have a tensile strength of 10 to 200 N / cm, preferably 15 to 200 N / cm, and more preferably 30 to 200 N / cm. Here, the tensile strength as used in the present invention means that it falls within this range in any direction.In other words, it does not mean the average of the vertical direction and the horizontal direction, and both the vertical direction and the horizontal direction are within this range. It means to enter. When the tensile strength is less than 10 N / cm, for example, when used for clothing, it easily breaks or deforms easily. On the other hand, if it exceeds 200 N / cm, the texture such as flexibility tends to be lowered, and it becomes difficult to balance the texture. The manufacturing method for obtaining these tensile strengths is not particularly limited, and the above-described manufacturing methods can be appropriately combined. For example, in general, if the basis weight increases, the tensile strength also increases. However, even if the basis weight is the same, if the needle punch method is applied as a three-dimensional entanglement method, the tensile strength decreases. Punching is preferable. Moreover, when a weight reduction process etc. are performed, a fabric weight will fall and tensile strength will also fall. Therefore, in the present invention, it is necessary to set manufacturing conditions in particular with a balance with bending rigidity and bending hysteresis.

  The tensile strength was measured according to JIS L 1096 8.12.1 (1999), a sample having a width of 5 cm and a length of 20 cm, and a tensile speed of 10 cm / min with a constant-speed extension type tensile tester with a gripping interval of 10 cm. And stretched. From the obtained value, the load per 1 cm width was defined as tensile strength (unit: N / cm).

  Thus, only by balancing the single fiber fineness, bending stiffness, bending hysteresis, tensile strength, basis weight within the scope of the present invention, it can be a long-fiber nonwoven fabric having flexibility and tensile strength, suitable texture, In particular, it can be suitably used for apparel that has not been sufficiently developed until now. Here, the clothes are not particularly limited, for example, sports clothes, disposable clothes, surgical clothes, and the like, and can be variously applied alone or as various coatings and base fabrics for lamination.

Hereinafter, the present invention will be described in more detail with reference to examples. In addition, the physical-property value in an Example was measured by the method described below.
(1) Hollow ratio of composite fiber 100 composite fiber cross sections were randomly observed with an optical microscope, and the ratio of the area of the hollow portion in the area of the single fiber was measured and averaged to obtain the hollow ratio.
(2) Single fiber fineness 100 cross-sections of single fibers were randomly observed with an optical microscope, and calculated from the averaged area and the specific gravity of the fibers. The specific gravity was measured based on JIS L 1015 (1999).
(3) Flexural rigidity and flexural hysteresis By using KES-FB2 system (pure bending tester) manufactured by Kato Tech Co., Ltd., arbitrarily sampling three locations, measuring in the vertical and horizontal directions, obtaining the average value, flexural rigidity The value of bending hysteresis was used. The torque sensitivity (SENS) in the system at this time was set to “2 × 1” (standard), and measurement was performed under conditions of 25 ° C. and humidity 60%.
(4) Weight per unit area, apparent density Per unit area was measured by the method of JIS L 1096 8.4.2 (1999). Further, the thickness was measured with a dial thickness gauge (manufactured by Ozaki Mfg. Co., Ltd., trade name “Peacock H”), and the apparent density was calculated from the basis weight value.
(5) Tensile strength According to JIS L 1096 8.12.1 (1999), a sample having a width of 5 cm and a length of 20 cm was taken, and a tensile rate of 10 cm / min was obtained with a constant-speed extension type tensile tester with a gripping interval of 10 cm. And stretched. From the obtained value, the load per 1 cm width was defined as tensile strength.

Example 1
Using a polyethylene terephthalate (inherent viscosity 0.66) and nylon 6 (relative viscosity 2.40), using a rectangular die having a fiber section of 24 segments similar to the cross-sectional shape shown in FIG. After spinning at a spinning temperature of 290 ° C., it was collected on a net conveyor (collecting sheet) under suction at a spinning speed of 4650 m / min using a rectangular ejector (ejector pressure 0.35 MPa). At this time, the fibers collected on the net conveyor were collected and observed. As a result, the single fiber fineness of the composite fiber was 2.4 dtex and the hollowness was 9%.

Subsequently, the web (100 g / m ² basis weight) collected on the net conveyor was temporarily set at 150 ° C., which is lower than the melting point of the polymer, under the condition of not being thermally bonded by a calendar press method. Next, after soaking in water, using a nozzle plate with nozzles with a hole diameter of 0.1 mm arranged at intervals of 0.6 mm, a water jet punch (WJP) was used at a processing speed of 1 m / min. The surface not in contact with the conveyor) The treatment was performed 5 times in the order of 4 MPa, back 10 MPa, front 10 MPa, back 20 MPa, and front 20 MPa. The surface of the obtained nonwoven fabric was almost entirely divided, and the single fiber fineness was about 0.1 dtex.

  The long-fiber nonwoven fabric thus obtained was measured for bending stiffness, bending hysteresis, basis weight, apparent density, and tensile strength, and the results are shown in Table 1. The nonwoven fabric thus obtained was dense and flexible and had a texture that could be applied to clothing.

Example 2
After water jet punching, it was treated with a 3% aqueous solution of sodium hydroxide at 90 ° C. to remove 20% of the total weight. About the obtained long fiber nonwoven fabric, the physical property similar to Example 1 was evaluated, and the result was shown in Table 1. Compared with the nonwoven fabric obtained in Example 1, the nonwoven fabric obtained by this was further soft and had a good texture.

Example 3
A long-fiber nonwoven fabric was obtained in the same manner as in Example 2 except that the weight loss rate was 40%. About the obtained long fiber nonwoven fabric, the physical property was evaluated similarly to Example 1, and the result was shown in Table 1. Compared with the nonwoven fabric obtained in Example 2, the nonwoven fabric obtained in this way is more flexible and has a moderate rebound, and has a texture comparable to conventional clothing fabrics. It was.

Example 4
The long-fiber nonwoven fabric obtained in Example 1 was dyed at 95 ° C. for 40 minutes using an acid dye (Lanacron Navy Blue GG, manufactured by Ciba Specialty Chemicals Co., Ltd., 10% owf) using a liquid dyeing machine. Fixing and cleaning were performed at The physical properties of this nonwoven fabric were evaluated in the same manner as in Example 1, and the results are shown in Table 1. The obtained non-woven fabric became very soft compared to before dyeing, and became a preferable texture for clothing.

Comparative Example 1
The same web as in Example 1 was processed in the same manner as in Example 1 except that the web was heat-bonded at 230 ° C. with an embossed calendar having a convex area of 18%. The surface of the obtained long fiber nonwoven fabric was present without dividing the heat-bonded portion. About this nonwoven fabric, the physical property was evaluated similarly to Example 1, and the result was shown in Table 1. The nonwoven fabric thus obtained was firm and unsuitable for use in clothing and the like.

Comparative Example 2
In Example 1, a needle punch was used instead of a water jet punch, and processing was performed at an implantation density of 500 pieces / cm ² . About the obtained long fiber nonwoven fabric, the physical property was evaluated similarly to Example 1, and the result was shown in Table 1. The resulting nonwoven fabric had a soft texture, but the fibers fell off due to stagnation, and the tensile strength was not satisfactory.

Comparative Example 3
The treatment was performed in the same manner as in Example 1 except that the discharge rate and the feed speed of the net conveyor were increased so that the single fiber fineness of the composite fiber was 4.8 dtex, and the treatment speed of the water jet punch was 15 m / min. About the obtained nonwoven fabric, the physical property similar to Example 1 was evaluated, and the result was shown in Table 1. The resulting non-woven fabric was somewhat stiff, had no rebound, had a stiff texture, and was unsuitable for clothing.

Comparative Example 4
The processing was carried out in the same manner as in Example 1 except that the spinning speed was kept as it was, the speed of the net conveyor was increased, and the basis weight of the web was adjusted to 25 g / m ² . About the obtained nonwoven fabric, the physical property similar to Example 1 was evaluated, and the result was shown in Table 1. The nonwoven fabric thus obtained was soft but lacked a sense of fulfillment and was unsatisfactory for use in clothing.

It is sectional drawing which shows an example of the composite fiber which comprises the long-fiber nonwoven fabric of this invention. It is sectional drawing which shows another example which comprises the long fiber nonwoven fabric of this invention. It is sectional drawing which shows another example which comprises the long fiber nonwoven fabric of this invention. It is sectional drawing which comprises the long-fiber nonwoven fabric of this invention, and shows another example. It is sectional drawing which comprises the long-fiber nonwoven fabric of this invention, and shows another example.

Explanation of symbols

1: Component A
2: Component B
3: Hollow part

Claims (11)

The single fiber fineness is 0.001 to 1.0 dtex, the bending stiffness measured by the KES-FB2 system is 0.1 to 8 × 10 ⁻³ Ncm ² / cm, and the bending hysteresis is 0.1 to 15 A long fiber nonwoven fabric characterized by × 10 ⁻³ Ncm / cm, tensile strength of 10 to 200 N / cm, and basis weight of 50 to 400 g / m ² . The long-fiber non-woven fabric according to claim 1, comprising at least two kinds of fibers. The long-fiber nonwoven fabric according to claim 1 or 2, comprising a polyamide-based fiber and / or a polyester-based fiber. The long fiber nonwoven fabric according to any one of claims 1 to 3, which has an apparent density in the range of 0.2 to 0.5 g / cm ³ . The long-fiber nonwoven fabric according to any one of claims 1 to 4, wherein the nonwoven fabric is used for clothing. The long fiber nonwoven fabric according to any one of claims 1 to 5, which is substantially not thermally bonded. The long fiber nonwoven fabric according to any one of claims 1 to 6, wherein at least one component is dyed. A long-fiber nonwoven fabric composed of split composite long fibers of at least two components is subjected to a water jet punch until it has an apparent density of 0.2 to 0.6 g / cm ³ , and then the split composite A method for producing a long-fiber nonwoven fabric, comprising removing at least one component of long fibers. The process pressure of this water jet punch is 10-30 Mpa, The manufacturing method of the long-fiber nonwoven fabric of Claim 8 characterized by the above-mentioned. The method for producing a long-fiber nonwoven fabric according to claim 8 or 9, wherein the removal dissolves and removes 10 to 60% of the total weight of the long-fiber nonwoven fabric. It dyes | stains with a liquid dyeing machine, The manufacturing method of the long fiber nonwoven fabric in any one of Claims 8-10 characterized by the above-mentioned.

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