JP2005526919A - 接着可能な配向不織繊維ウェブおよびその製造方法 - Google Patents
接着可能な配向不織繊維ウェブおよびその製造方法 Download PDFInfo
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Abstract
Description
図1〜3に示されるような装置を使用して、0.60の固有粘度を有するポリエチレンテレフタレート(3MのPET樹脂651000)から4つの異なる繊維ウェブを調製した。4つの実施例のそれぞれにおいて、PETを押出機内で270℃に加熱し(押出機12内のポンプ13への出口付近で測定した温度)、ダイを以下の表1に記載される温度に加熱した。押出ヘッドまたはダイは4列のオリフィスを有し、それぞれの列は21個のオリフィスを有し、全部で84個のオリフィスが形成された。ダイは横断方向の長さが4インチ(101.6ミリメートル)であった。孔の直径は0.035インチ(0.889mm)であり、L/D比は6.25であった。ポリマーの流速は1.6g/孔/分であった。
図1〜3に示されるような装置において、ポリブチルテレフタレート(チコナ(Ticona)により供給されるPBT−1、密度1.31g/cc、融点227℃、およびガラス転移温度66℃)から繊維ウェブを調製した。押出機の温度を245℃に設定し、ダイの温度を240℃にした。ポリマーの流速は1グラム/孔/分であった。ダイとアッテネータの間の距離は14インチ(約36センチメートル)であり、アッテネータからコレクタまでの距離は16インチ(約41センチメートル)であった。更なる条件は表4に記載され、他のパラメータは、概略的に、実施例1〜4で与えられた通りであった。
透明な種類のPTT(シェル・ケミカルズ(Shell Chemicals)により供給されるCP509201)(実施例9〜11)と、0.4%のTiO2を含有する種類(CP509211)(実施例12〜14)とを用いて、ポリトリメチレンテレフタレート(PTT)繊維のウェブを図1〜3に示されるような装置で調製した。押出ダイは実施例1〜4に記載した通りであり、以下の表5に記載されるような温度に加熱した。ポリマーの流速は1.0グラム/孔/分であった。
図1〜3に示されるような装置、および以下の点を除いて実施例1〜4に記載した通りのダイおよびアッテネータにおいて、ポリ乳酸(カーギル・ダウ(Cargill−Dow)により供給されるグレード625OD)の繊維を製造した。押出機およびダイの温度は240℃に設定した。ダイとアッテネータの間の距離は12インチ(約30.5センチメートル)であり、アッテネータとコレクタの間は25インチ(63.5センチメートル)であった。アッテネータの上部間隙は0.168インチ(4.267mm)であり、底部間隙は0.119インチ(3.023mm)であった。捕集したウェブを55℃のオーブン内で10分間接着させた。ウェブ中の繊維は、変化するモルホロジーを示し、自己接着された。
図1〜3に描かれるような装置を用いて、メルトフローインデックス70を有するポリプロピレン(フィナ(Fina)3860))から繊維ウェブを調製した。ポリマー流速が0.5g/孔/分であり、ダイが0.343mm直径の168個のオリフィスを有し、オリフィスのL/D比が3.5であり、上部および底部におけるアッテナータ間隙が7.67mmであり、ダイからアッテネータまでの距離が108mmであり、アッテネータからコレクタまでの距離が991mmであった点を除いて、パラメータは、概して、実施例1〜4に記載した通りであった。
図1〜3に示されるような装置および実施例1〜4に記載された通りのダイを用いて、ナイロン6樹脂(BASFにより供給されるウルトラミッド(Ultramid)B3)から繊維ウェブを製造した。押出機およびダイの温度を270℃に設定した。ポリマー流速は1.0g/孔/分であった。ダイとアッテネータの間の距離は13インチ(約33センチメートル)であり、アッテネータとコレクタの間は25インチ(63.5センチメートル)であった。アッテネータの上部間隙は0.135インチ(3.429mm)であり、底部間隙は0.112インチ(2.845mm)であった。シュート長さは167.4ミリメートルであった。アッテネータを通る空気流は142SCFM(4.021ACMM)であった。捕集したウェブを、コレクタ上で一線に、温度220℃の空気を用いる前面速度が100メートル/分より大きいホットエアナイフによって接着させた。
図1〜3の装置および実施例1〜4に記載されたような押出ダイを用いて、ポリウレタン(モートン(Morton)PS−440−200、MFI37)から不織繊維ウェブを調製した。ポリマー処理能力は1.98g/孔/分であった。アッテネータは基本的に実施例1〜4に記載されたとおりであり、0.196インチ(4.978mm)の上部間隙、および0.179インチ(4.547mm)の底部間隙を有した。アッテネータを通過される空気の容積は3ACMMより大きかった。アッテネータは、ダイより12.5インチ(31.75cm)下であり、コレクタより24インチ(約61cm)上であった。直径が平均14.77マイクロメートルの繊維を含むウェブを捕集しながら自己接着させ、更なる接着工程は必要とされない、または実行しなかった。
図1〜3に示されるような装置および実施例1〜4に記載されるような押出ダイを用いて、MFI30および密度0.95を有するポリエチレン(Dow6806)からポリエチレン不織繊維ウェブを調製した。押出機およびダイの温度を180℃に設定した。処理能力は1.0g/孔/分であった。アッテネータは基本的に実施例1〜4に記載された通りであり、ダイより15インチ(約38センチメートル)下で、コレクタより20インチ(約51センチメートル)上に配置した。アッテネータの間隙は、上部で0.123インチ(3.124mm)、底部で0.11インチ(2.794mm)であった。アッテネータを通る空気流は113SCFM(3.2ACMM)であった。135℃の温度の空気および100メートル/分より速い前面速度を用いるホットエアナイフによって、捕集されたウェブを接着させた。
ダイが168個のオリフィスを有し、オリフィスの直径が0.508ミリメートルであり、アッテネータ間隙が、上部で3.20ミリメートル、底部で2.49ミリメートルであり、シュートの長さが228.6ミリメートルであり、アッテネータを通る空気流が2.62ACMMであり、アッテネータからコレクタまでの距離が約61センチメートルであった点を除いて、実施例19を繰り返した。
図1〜3に示されるような装置を使用し、環状オレフィンポリマー(チコナからのTOPAS6017)を用いて非晶質高分子繊維を調製した。ポリマーを押出機中で320℃に加熱し(押出機12内のポンプ13への出口付近で測定した温度)、ダイを320℃の温度に加熱した。押出ヘッドまたはダイは、それぞれの列が42個のオリフィスを有する4つの列を有し、全部で168個のオリフィスが形成された。ダイは横断方向の長さが4インチ(102ミリメートル(mm))であった。オリフィスの直径は0.020インチ(0.51mm)であり、L/D比は6.25であった。ポリマーの流速は1.0g/オリフィス/分であった。
図1〜3に示されるような装置を使用し、メルトフローインデックス15.5および密度1.04を有するポリスチレン(ノバ・ケミカルズ(Nova Chemicals)からのクリスタル(Crystal)PS3510)を用いて非晶質高分子繊維を調製した。ポリマーを押出機中で268℃に加熱し(押出機12内のポンプ13への出口付近で測定した温度)、ダイを268℃の温度に加熱した。押出ヘッドまたはダイは、それぞれの列が42個のオリフィスを有する4つの列を有し、全部で168個のオリフィスが形成された。ダイは横断方向の長さが4インチ(102ミリメートル)であった。オリフィスの直径は0.343mmであり、L/D比は9.26であった。ポリマーの流速は1.00g/オリフィス/分であった。
図1〜3に示されるような装置を使用し、メルトフローインデックス8および密度0.9を有する13%スチレンおよび87%エチレンブチレンコポリマーのブロックコポリマー(シェルからのKRATON G1657)を用いて非晶質高分子繊維を調製した。ポリマーを押出機中で275℃に加熱し(押出機12内のポンプ13への出口付近で測定した温度)、ダイを275℃の温度に加熱した。押出ヘッドまたはダイは、それぞれの列が42個のオリフィスを有する4つの列を有し、全部で168個のオリフィスが形成された。ダイは横断方向の長さが4インチ(101.6ミリメートル)であった。オリフィスの直径は0.508mmであり、L/D比は6.25であった。ポリマーの流速は0.64g/オリフィス/分であった。
図1〜3に示されるような装置を使用し、ポリカーボネート(ゼネラルエレクトリック(General Electric)のSLCC HF1110P樹脂)を用いて非晶質高分子繊維を調製した。ポリマーを押出機中で300℃に加熱し(押出機12内のポンプ13への出口付近で測定した温度)、ダイを300℃の温度に加熱した。押出ヘッドまたはダイは、それぞれの列が21個のオリフィスを有する4つの列を有し、全部で84個のオリフィスが形成された。ダイは横断方向の長さが4インチ(102ミリメートル)であった。オリフィスの直径は0.035インチ(0.889mm)であり、L/D比は3.5であった。ポリマーの流速は2.7g/オリフィス/分であった。
図1〜3に示されるような装置を使用し、ポリスチレン(BASFポリスチレン145D樹脂)を用いて非晶質高分子繊維を調製した。ポリマーを押出機中で245℃に加熱し(押出機12内のポンプ13への出口付近で測定した温度)、ダイを245℃の温度に加熱した。押出ヘッドまたはダイは、それぞれの列が21個のオリフィスを有する4つの列を有し、全部で84個のオリフィスが形成された。ダイは横断方向の長さが4インチ(101.6ミリメートル)であった。オリフィスの直径は0.035インチ(0.889mm)であり、L/D比は3.5であった。ポリマーの流速は0.5g/オリフィス/分であった。
Claims (16)
- 選択された接着動作中に独特の軟化特性の長手方向セグメントを提供するようにその長さに沿ってモルホロジーが変化する、直接捕集された均一な直径の繊維塊を含む接着不織繊維ウェブであって、前記接着動作条件下で軟化して前記ウェブの他の繊維と接着するセグメントもあれば、前記接着動作の間、受動的なセグメントもある接着不織繊維ウェブ。
- モルホロジーが変化する前記繊維が、鎖延長型の結晶化を示すセグメントを含む請求項1に記載の繊維ウェブ。
- 自己接着によって接着された請求項1または2に記載のウェブ。
- 前記接着が、他の繊維との周囲浸透性の接着を含む請求項3に記載の繊維ウェブ。
- モルホロジーが変化する前記繊維は、複屈折が少なくとも5%異なる長手方向セグメントを含む請求項1〜4のいずれか一項に記載のウェブ。
- モルホロジーが変化する前記繊維は、複屈折が少なくとも10%異なる長手方向セグメントを含む請求項1〜5のいずれか一項に記載のウェブ。
- 本明細書中に記載される傾斜密度試験において、前記繊維の少なくとも5つの繊維断片が、水平から少なくとも30度の角度に配置されるようになる請求項1〜6のいずれか一項に記載のウェブ。
- 本明細書中に記載される傾斜密度試験において、前記繊維の少なくとも5つの繊維断片が、水平から少なくとも60度の角度に配置されるようになる請求項1〜6のいずれか一項に記載のウェブ。
- 本明細書中に記載される傾斜密度試験において、前記繊維の少なくとも半分の繊維断片が、水平から少なくとも30度の角度に配置されるようになる請求項1〜6のいずれか一項に記載のウェブ。
- 本明細書中に記載される傾斜密度試験において、モルホロジーが変化する前記繊維の少なくとも半分の繊維断片が、水平から少なくとも60度の角度に配置されるようになる請求項1〜6のいずれか一項に記載のウェブ。
- モルホロジーが変化する前記繊維が、約10マイクロメートル以下の平均直径を有する請求項1〜10のいずれか一項に記載のウェブ。
- 少なくとも90パーセントの堅さの嵩高性を有する請求項1〜11のいずれか一項に記載のウェブ。
- モルホロジーが変化する前記繊維に加えてその他の繊維も含む請求項1〜12のいずれか一項に記載のウェブ。
- a)繊維形成材料のフィラメントを押出すことと、b)気体流が長手方向の応力を前記フィラメントに加える処理チャンバを介して、前記フィラメントを方向付けることと、c)前記フィラメントが処理チャンバを出た後に、前記フィラメントを乱流条件下に置くことと、d)処理されたフィラメントを捕集することとを含む繊維形成方法であって、
前記フィラメントの少なくともいくつかが乱流場にある間に凝固するように、前記フィラメントの温度が制御される方法。 - 前記繊維が不織繊維ウェブとして捕集されて接着動作を受け、この間に軟化して他の繊維と接着する繊維の長手方向セグメントもあれば、接着動作の間、受動的なままである長手方向セグメントもある請求項14に記載の方法。
- 前記繊維が不織繊維ウェブとして捕集されて自己接着動作を受け、この間に軟化して他の繊維と接着する繊維の長手方向セグメントもあれば、接着動作の間、受動的なままである長手方向セグメントもある請求項14に記載の方法。
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AU2003223614A1 (en) | 2003-12-12 |
US20050161156A1 (en) | 2005-07-28 |
TW200404931A (en) | 2004-04-01 |
US6916752B2 (en) | 2005-07-12 |
DE60318203D1 (de) | 2008-01-31 |
WO2003100141A1 (en) | 2003-12-04 |
CN1656260B (zh) | 2012-03-21 |
KR100980535B1 (ko) | 2010-09-06 |
CA2486414A1 (en) | 2003-12-04 |
CN1656260A (zh) | 2005-08-17 |
US7695660B2 (en) | 2010-04-13 |
JP4594082B2 (ja) | 2010-12-08 |
DE60318203T2 (de) | 2009-01-08 |
IL164917A0 (en) | 2005-12-18 |
EP1509643B1 (en) | 2007-12-19 |
KR20050007410A (ko) | 2005-01-17 |
BR0311134A (pt) | 2005-02-22 |
AU2003223614B2 (en) | 2007-08-30 |
TWI319022B (en) | 2010-01-01 |
US20030216096A1 (en) | 2003-11-20 |
ATE381631T1 (de) | 2008-01-15 |
MXPA04011370A (es) | 2005-02-17 |
ZA200410158B (en) | 2005-10-06 |
EP1509643A1 (en) | 2005-03-02 |
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