JP2013522497A - Non woven web - Google Patents

Abstract

  A nonwoven web comprising bicomponent fibers. The fiber has a continuous phase of each of the first polyarylene sulfide (PAS) component and the polymer component. The polymer component may also be a second polyarylene sulfide. The first polyarylene sulfide component contains tin or zinc additives or both, and the first polyarylene sulfide component of any given fiber is at least partially exposed to the outer surface of the fiber.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a priority of US Provisional Patent Application No. 61 / 316,061, filed Mar. 22, 2010, which is hereby incorporated by reference in its entirety. Insist on profit.

  The present invention relates to nonwoven webs, particularly webs formed from polyarylene sulfide.

  It is known that the physical properties of the web can be improved by calendering, which passes the sheet material through a nip between rolls or plates to give the sheet material a smooth glossy appearance. Or otherwise improve the selected physical property.

  Calendering paper or other fibrous material to further improve the quality of the formed paper, or to provide a higher level of quality, resulting in faster operating speeds or higher paper bulk produced Efforts are being made to do this. It is known that the plasticity or formability of paper or fiber can be increased by increasing the temperature and / or plasticizer content of the paper or fiber. The temperature of the polymer contained in the paper is the so-called glass transition temperature (T.sub.g) (at the glass transition temperature, the material is molded or formed or finished more easily than is possible at temperatures below that temperature. When it rises or exceeds it, significant changes in mechanical properties, including plasticity, occur.

  Many nonwovens are bonded to impart integrity to the fabric. There are several bonding techniques available, but the thermal bonding process is mainstream in the nonwoven industry in terms of both the amount and time devoted to new product research and development. These processes are widely accepted due to their many advantages over simplicity and conventional chemical bonding methods. Attractive features include low energy and raw material costs, high production rates, and product versatility. Since no adhesive binder is used, chemical concerns are simplified and environmental concerns are reduced. Patent Documents 1 and 2 provide examples of point bonding of nonwoven webs that enhance physical properties.

  In Patent Document 3, fusible and fusible fibers of similar denier and cut length are blended, and the web is treated with a solvent or heat to produce a non-woven fabric. The idea of using fibers has been introduced. The fusible fiber becomes tacky and acts as a binder. After the adhesive web is pressed and cooled, it becomes a nonwoven fabric.

  Using temperatures close to the melting point (Tm) of the fibers in the nanoweb is detrimental to web quality. Small size fibers combined with the non-uniform heating inherent in calenders tend to cause non-uniform melting and bonding and the web tends to be ineffective for filtration and battery separators and other energy storage applications. The disadvantages in the prior art in the field of reinforcing webs with low basis weight and comprising fine denier fibers are exemplified in US Pat. No. 5,057,099, which uses a thermal bond in a pattern to create a web that is difficult to deform. Generated.

  The present invention overcomes the shortcomings of conventional processes for making calendered webs by providing a process that provides a high strength product under less severe conditions.

US Pat. No. 4,035,219 US Pat. No. 5,424,115 US Pat. No. 2,277,049 (granted to Reed) EP 1 042 549

  The present invention relates to a nonwoven web comprising bicomponent fibers, said fibers comprising a continuous phase of a first polyarylene sulfide (PAS) component and a polymer component, wherein the first polyarylene sulfide component is tin. Or a zinc additive or both, and the first polyarylene sulfide component of any particular fiber is at least partially exposed on the outer surface of the fiber. “Partially exposed” means that at least some of the components appear on the outer surface of the fiber. All outer surfaces of the fiber may be the first PAS component and may at least partially cover the polymer component.

  The present invention relates to (i) a step of spinning bicomponent fibers into a nonwoven web, wherein the fibers comprise a continuous phase of a first polyarylene sulfide component and a polymer component, and the first polyarylene sulfide component A tin or zinc additive or both, wherein the first polyarylene sulfide component of any particular fiber is at least partially exposed to the outer surface of the fiber, (ii) calendar the nonwoven web It also relates to an improved process for producing a nonwoven web comprising processing to bond at least a portion of individual fibers. In certain embodiments, the nonwoven web is calendered at a time and temperature sufficient to bond at least a portion of the individual fibers.

  Where the indefinite article "a" or "an" relates to a description or description of the existence of a step in the process of the invention, the use of such indefinite article is a step in the process, unless explicitly stated otherwise in the description or description. It is understood that the presence of is not limited to one by number.

  When numerical ranges are listed herein, unless otherwise specified, the ranges are meant to include their endpoints and all integers and fractions within the ranges. It is not intended that the scope of the invention be limited to the specific values recited when defining a range.

Definitions The term “spunbond” as used herein refers to, for example, US Pat. No. 4,340,563 (assigned to Appel et al.) And US Pat. No. 3,692,618 (assigned to Dorschner et al.). ), US Pat. No. 3,802,817 (assigned to Matsuki et al.), US Pat. No. 3,338,992 and US Pat. No. 3,341,394 (assigned to Kinney), US No. 3,542,615 (provided to Dobo et al.), Which is the diameter of a rapidly reduced extruded filament as in the entirety of each of which is hereby incorporated by reference. It means a small diameter fiber formed by extruding a molten thermoplastic material as a filament from a plurality of thin normal circular capillaries of a spinneret.

  As used herein, the term “melt blow” refers to a melted thermoplastic material as a melted yarn or filament, which is passed through a plurality of thin normal circular capillaries to reduce the diameter of the melted thermoplastic material filaments. By fibers are formed by extruding into a high velocity gas (eg, air) stream that reduces (to the microfiber diameter). Thereafter, the meltblown fibers are carried in a high velocity gas stream and are deposited on the collection surface to form a web in which the meltblown fibers are randomly dispersed. Such a process is described in NRL Report 4364, “Manufacture of Super-Fine Organic Fibers” (BA Wendt, E. L. Boone, and D. D. Fluharty); of Super-Fine Thermoplastic Fibers "(K.D. Lawrence, RT.Lukas, JA.Young; and U.S. Pat. No. 3,849,241 issued to Butin et al. (Which patent is incorporated herein by reference in its entirety) and is disclosed in various patent documents and publications.

  As used herein, the term “multicomponent fiber” is formed from at least two component polymers extruded from separate extruders, or similar polymers having different properties or additives, but spun together. Means a fiber that forms one type of fiber. Multicomponent fibers may also be referred to as conjugate fibers or bicomponent fibers. The polymer is arranged in discrete regions that are arranged substantially uniformly throughout the cross-section of the multicomponent fiber and extends substantially continuously along the length of the multicomponent fiber. Such a multi-component fiber configuration may be, for example, a sheath / core arrangement in which one polymer is surrounded by another polymer, or a side-by-side, “sea-island” arrangement, and a pie-wedge shape. (Pie-wedge shape) or as stripes on circular, oval or rectangular cross-section fibers. Multicomponent fibers are described, for example, in US Pat. No. 5,108,820 (assigned to Kaneko et al.), US Pat. No. 5,336,552 (assigned to Track et al.), And US Pat. No. 5,382. , 400 (assigned to Pike et al.). For bicomponent fibers, the polymer may be present in any desired ratio.

  As used herein, the term “bicomponent fiber” or “multicomponent fiber” refers to from at least two polymers extruded from the same extruder as a blend, or from the same type of polymer having different properties or additives. Refers to the fibers that are formed, and the polymer is not arranged in discrete regions that are arranged substantially uniformly throughout the cross-section of the multicomponent fiber. This general type of fiber is discussed, for example, in US Pat. No. 5,108,827 (given to Gessner).

  The term “nonwoven web” or “nonwoven material” as used herein refers to the structure of individual fibers or filaments interlaid rather than in an identifiable manner as in a knitted or woven fabric. Means a web with Nonwoven webs have been formed from many methods such as, for example, meltblowing, spunbonding, air laying and carded web methods. The basis weight of a nonwoven is usually expressed in grams / square meter (gsm) or ounces / square yard (osy) of the material, and the useful diameter of the fiber is usually expressed in microns. (However, to convert from osy to gsm, osy is multiplied by 33.91).

  “Partially covering” means that one component of a bicomponent or multicomponent fiber at least partially covers the second component. One component may appear on the outer surface of the fiber.

  “Calendaring” is the process of passing a web through a nip between two rolls. The rolls may contact each other or there may be a fixed or variable gap between the roll surfaces. In the calendering process of the present invention, it is advantageous if the nip is formed between a soft roll and a hard roll. A “soft roll” is a roll that deforms under pressure applied to hold the two rolls together in a calendar. A “hard roll” is a roll having a surface that does not undergo any deformation that significantly affects the process or product under the pressure of the process. The hard roll may have a pattern embossed on it or may not be embossed. “Unembossed” rolls are rolls that have a smooth surface within the capabilities of the process used to produce them. Unlike point-bonding rolls, there is no point or pattern that intentionally creates a pattern on the web as it passes through the nip.

  Polyarylene sulfides (PAS) include linear, branched or cross-linked polymers containing arylene sulfide units. Polyarylene sulfide polymers and their syntheses are known in the art and such polymers are commercially available.

Representative polyarylene sulfides useful in the present invention include those of the formula-[(Ar ¹ ) _n- X] _m -[(Ar ² ) _i Y] _j- (Ar ³ ) _k -Z] ₁ -[(Ar ⁴ ) _O -W] _p- [wherein Ar ¹ , Ar ² , Ar ³ and Ar ⁴ are the same or different and are arylene units having 6 to 18 carbon atoms; W, X, Y, and Z Are the same or different and are selected from —SO ₂ —, —S—, —SO—, —CO—, —O—, —COO— or an alkylene or alkylidene group having 1 to 6 carbon atoms. A linking group, at least one of the linking groups is -S-; and n, m, i, j, k, l, o, and p are independently 0 or 1, 2, 3, or 4 (however, their sum is not less than 2)] Polyarylene thioethers and the like that. Arylene units Ar ¹ , Ar ² , Ar ³ and Ar ⁴ may be optionally substituted or unsubstituted. Preferred arylene systems are phenylene, biphenylene, naphthylene, anthracene and phenanthrene. The polyarylene sulfide typically comprises at least 30 mol%, in particular at least 50 mol%, more particularly at least 70 mol% of arylene sulfide (-S-) units. It is preferred that the polyarylene sulfide polymer comprises at least 85 mol% sulfide bonds directly bonded to the two aromatic rings. The polyarylene sulfide polymer is advantageously polyphenylene sulfide (PPS). In the present specification, the phenylene sulfide structure — (C ₆ H ₄ —S) _n— [wherein n is 1 Or an integer greater than or equal to].

  It is preferable that a polyarylene sulfide polymer having one kind of arylene group as a main component can be used. However, in consideration of processability and heat resistance, a copolymer containing two or more types of arylene groups can also be used. A PPS resin comprising a p-phenylene sulfide repeating unit as a main constituent element is particularly preferable because it has excellent processability and is easily available in the industry. Furthermore, polyarylene ketone sulfide, polyarylene ketone ketone sulfide, polyarylene sulfide sulfone and the like can also be used.

  Specific examples of possible copolymers include random or block copolymers having p-phenylene sulfide repeat units and m-phenylene sulfide repeat units, random or block copolymers having phenylene sulfide repeat units and arylene ketone sulfide repeat units, phenylene sulfide repeats Random or block copolymers having units and arylene ketone ketone sulfide repeat units, and random or block copolymers having phenylene sulfide repeat units and arylene sulfone sulfide repeat units.

  Polyarylene sulfides may optionally include other components that do not adversely affect their desired properties. Representative materials that can be used as additional ingredients include antibacterial agents, pigments, antioxidants, surfactants, waxes, flow promoters, particulates, and other substances added to promote processability of the polymer (But not limited to). These and other additives can be used in conventional amounts.

DESCRIPTION The present invention relates to a nonwoven web comprising bicomponent fibers, wherein the fibers comprise a continuous phase of a first polyarylene sulfide (PAS) component and a second polymer component, respectively, the first polyarylene sulfide component. Contains tin or zinc additives or both, and the first polyarylene sulfide component of any given fiber is at least partially exposed to the outside of the fiber. “Partially exposed” means that at least some of the components appear on the outer surface of the fiber. All outer surfaces of the fibers may be composed of the first PAS component. The first PAS component may at least partially cover the second polymer component.

  The present invention is a step of (i) spinning a bicomponent fiber into a nonwoven web, wherein the fiber comprises a continuous phase of each of a first polyarylene sulfide component and a second polymer component, the first polyarylene The sulfide component contains tin or zinc additives or both, and the first polyarylene sulfide component of any given fiber is at least partially exposed to the outside of the fiber; (ii) individual fibers And an improved process for producing a nonwoven web comprising calendering the nonwoven web at a time and temperature sufficient to bond at least a portion of the web.

  The spinning process of the present invention can be any nonwoven spinning process known to those skilled in the art (eg, spunbonding or meltblowing).

  The second polymer component can comprise any thermoplastic polymeric material. In further embodiments, the second polymer component may comprise a polymer selected from the group consisting of polyetheretherketone (PEEK), polyetherketone (PEK), polyester, polypropylene, polyamide, and mixtures thereof. Is possible. The polyester is preferably polyethylene terephthalate (PET), polytrimethylene terephthalate, or polybutylene terephthalate (PBT). The second polymer component can further comprise a second PAS, and the second PAS may comprise a calcium salt additive, preferably calcium stearate.

In one embodiment, the first PAS component of the fiber sheath comprises at least one tin (II) salt of an organic carboxylic acid. The polyarylene sulfide composition is selected from the group consisting of Sn (O ₂ CR) ₂ , Sn (O ₂ CR) (O ₂ CR ′), Sn (O ₂ CR) (O ₂ CR ″), and mixtures thereof. And at least one tin additive comprising a branched tin (II) carboxylate, wherein the carboxylate moieties O ₂ CR and O ₂ CR ′ are independently branched carboxy Represents the late anion, and the carboxylate moiety O ₂ CR ″ represents the linear carboxylate anion. In one embodiment, the branched tin (II) carboxylate comprises Sn (O ₂ CR) ₂ , Sn (O ₂ CR) (O ₂ CR ′), or a mixture thereof. In one embodiment, the branched tin (II) carboxylate comprises Sn (O ₂ CR) ₂ . In one embodiment, the branched tin (II) carboxylate comprises Sn (O ₂ CR) (O ₂ CR ′). In one embodiment, the branched tin (II) carboxylate comprises Sn (O ₂ CR) (O ₂ CR ″).

Optionally, the tin additive may further comprise a linear tin (II) carboxylate Sn (O ₂ CR ″) _2. Generally, the sum of the branched carboxylate moieties [O ₂ Branched and linear, such that CR + O ₂ CR ′] is at least about 25%, based on moles of all carboxylate moieties [O ₂ CR + O ₂ CR ′ + O ₂ CR ″] contained in the additive. The relative amount of tin (II) carboxylate is selected. For example, the sum of the branched carboxylate moieties may be at least about 33%, or at least about 40%, or at least about 50%, or at least about 66%, or at least about 75% of all the carboxylate moieties included in the additive. Or at least about 90%.

In one embodiment, both radicals R and R ′ comprise 6 to 30 carbon atoms, and both contain at least one secondary or tertiary carbon. The secondary or tertiary carbon can be at any position of the carboxylate moieties O ₂ CR and O ₂ CR ′ (eg, α position relative to the carboxylate carbon, ω position relative to the carboxylate carbon, and any intermediate position). ). The free radicals R and R ′ may be unsubstituted and optionally substituted with inert groups (eg fluoride groups, chloride groups, bromide groups, iodide groups, nitro groups, hydroxyl groups, and carboxylate groups). Also good. Examples of suitable organic R and R ′ groups include aliphatic, aromatic, alicyclic, oxygen-containing heterocyclic, nitrogen-containing heterocyclic, and sulfur-containing heterocyclic radicals. Heterocyclic radicals may contain carbon and oxygen, nitrogen, or sulfur in the ring structure.

  In one embodiment, the free radical R ″ is a primary alkyl group comprising 6 to 30 carbon atoms and is an inert group (eg, a fluoride group, a chloride group, a bromide group, an iodide group). , A nitro group, a hydroxyl group, and a carboxylate group). In one embodiment, the free radical R "is a primary alkyl group comprising 6 to 20 carbon atoms. .

［式中、Ｒ_１、Ｒ_２、およびＲ_３は、独立して：
Ｈ；
場合によりフッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、ヒドロキシル基、およびカルボキシル基で置換されてもよい、６〜１８個の炭素原子を有する第１級、第２級、または第３級アルキル基；
場合によりフッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、ヒドロキシル基、およびカルボキシル基で置換されてもよい、６〜１８個の炭素原子を有する芳香族基；および
場合によりフッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、ヒドロキシル基、およびカルボキシル基で置換されてもよい、６〜１８個の炭素原子を有する脂環式基；であり
但し、Ｒ_２およびＲ_３が、Ｈである場合、Ｒ_１は、：
場合によりフッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、ヒドロキシル基、およびカルボキシル基で置換されてもよい、６〜１８個の炭素原子を有する第２級、または第３級アルキル基；
場合によりその芳香族基および／またはその第２級または第３級アルキル基は、フッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、ヒドロキシル基、およびカルボキシル基で置換されてもよい、６〜１８個の炭素原子を有する第２級または第３級アルキル基で置換された芳香族基；および
場合によりフッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、ヒドロキシル基、およびカルボキシル基で置換されてもよい、６〜１８個の炭素原子を有する脂環式基である］
によって表される構造を有する。 In one embodiment, the radicals R or R ′ independently or both are of the formula (I)

[Wherein R ₁ , R ₂ , and R ₃ are independently:
H;
Primary, secondary with 6-18 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups, Or a tertiary alkyl group;
An aromatic group having 6 to 18 carbon atoms, optionally substituted with a fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl group; and optionally a fluorine group. product group, chloride group, bromide group, an iodide group, a nitro group, a hydroxyl group, and may be substituted with a carboxyl group, an alicyclic group having 6 to 18 carbon atoms; a proviso, R ₂ And when R ₃ is H, R ₁ is:
Secondary or tertiary with 6 to 18 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups An alkyl group;
Optionally the aromatic group and / or the secondary or tertiary alkyl group may be substituted with a fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl group. Good, aromatic groups substituted with secondary or tertiary alkyl groups having 6 to 18 carbon atoms; and optionally fluoride groups, chloride groups, bromide groups, iodide groups, nitro groups, hydroxyl groups And an alicyclic group having 6 to 18 carbon atoms which may be substituted with a group and a carboxyl group]
It has the structure represented by.

In one embodiment, the free radical R or R ′ or both have a structure represented by formula (I) and R ₃ is H.

［式中、
Ｒ_４は、４〜６個の炭素原子を有する第１級、第２級、または第３級アルキル基であり、フッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、およびヒドロキシル基で場合により置換されてもよく；および
Ｒ_５は、メチル、エチル、ｎ−プロピル、ｓｅｃ−プロピル、ｎ−ブチル、ｓｅｃ−ブチル、またはｔｅｒｔ−ブチル基であり、フッ化物基、塩化物基、臭化物基、ヨウ化物基、ニトロ基、およびヒドロキシル基で場合により置換されてもよい］
によって表される構造を有する。 In another embodiment, the radical R or R ′ or both are of the formula (II)

[Where:
R ₄ is a primary, secondary, or tertiary alkyl group having 4 to 6 carbon atoms and is a fluoride, chloride, bromide, iodide, nitro, and hydroxyl group Optionally substituted with a group; and R ₅ is a methyl, ethyl, n-propyl, sec-propyl, n-butyl, sec-butyl, or tert-butyl group, a fluoride group, a chloride group Optionally substituted with bromide, iodide, nitro, and hydroxyl groups]
It has the structure represented by.

In one embodiment, the radicals R and R ′ are the same and both have the structure represented by formula (II), in which R ₄ is n-butyl and R ₅ is ethyl. This embodiment describes branched tin (II) carboxylate tin (II) 2-ethylhexanoate (also referred to herein as tin (II) ethylhexanoate).

  The tin (II) carboxylate may be obtained commercially or may be generated in situ from a suitable source of tin (II) cation and carboxylic acid depending on the desired carboxylate. The tin (II) additive may be present in the polyarylene sulfide at a concentration sufficient to provide improved thermal oxidative stability and / or thermal stability. In one embodiment, the tin (II) additive may be present at a concentration of about 10 weight percent or less based on the weight of the polyarylene sulfide. For example, the tin (II) additive may be present at a concentration of about 0.01 weight percent to about 5 weight percent, or such as from about 0.25 weight percent to about 2 weight percent. Typically, the concentration of tin (II) additive may be higher than in the masterbatch composition, for example from about 5 weight percent to about 10 weight percent or more. The tin (II) additive may be added to the molten or solid polyarylene sulfide as a solid, as a slurry, or as a solution.

  In a further embodiment, the fiber sheath polyarylene sulfide composition of the present invention further comprises at least one zinc (II) additive and / or zinc metal [Zn (0)]. The zinc (II) additive can be an organic compound (eg, zinc stearate) or an inorganic compound (eg, zinc sulfate or the like) as long as the organic or inorganic counterion does not adversely affect the desired properties of the polyarylene sulfide composition. Zinc oxide or the like). Zinc (II) additives may be obtained commercially or may be produced in situ. Zinc metal may be used in the composition alone or in combination with at least one zinc (II) additive as a source of zinc (II) ions. In one embodiment, the zinc (II) additive is selected from the group consisting of zinc oxide, zinc stearate, and mixtures thereof.

  The zinc (II) additive and / or zinc metal may be present in the polyarylene sulfide at a concentration of about 10 weight percent or less based on the weight of the polyarylene sulfide. For example, the zinc (II) additive and / or zinc metal may be present at a concentration of about 0.01 weight percent to about 5 weight percent, or such as from about 0.25 weight percent to about 2 weight percent. Typically, the concentration of the zinc (II) additive and / or zinc metal is higher than in the masterbatch composition, for example, from about 5 weight percent to about 10 weight percent or more. The at least one zinc (II) additive and / or zinc metal may be added to the molten or solid polyarylene sulfide, as a solid, as a slurry, or as a solution. The zinc (II) additive and / or zinc metal may be added together with the tin (II) salt or separately.

  A bicomponent spunbond fabric was made from a poly (ethylene terephthalate) (PET) component and a poly (phenylene sulfide) (PPS) component. The PET component has an intrinsic viscosity of 0.633 dl / g and is available as PET resin grade PQB8A-065 from PolyQuest (Wilmington, NC). The PPS component available from Ticona Engineering Polymers (Florence, KY) under the trade name Fortron® PPS was a mixture of 70 wt% grade 0309 C1 and 30 wt% grade 0317 C1.

  The following materials were used in the examples. Unless otherwise stated, all commercially available materials were used as received. Tin (II) 2-ethylhexanoate (90%) and zinc oxide (99%) were obtained from Sigma-Aldrich (St. Louis, MO). Tin (II) stearate (98%) (Sn stearate) was obtained from Acros Organics (Morris Plains, NJ). Zinc stearate (99%) (Zn stearate) was obtained from Honeywell Reidel-de Haen (Seelze, Germany). Tin (II) 2-ethylhexanoate is also referred to herein as tin (II) ethylhexanoate or SnEH.

  The additive was melt blended with PPS so that the additive (if used) comprises the required% of the total weight of the PPS component. The PET resin was dried in a ventilation dryer at a temperature of 120 ° C. to a water content of less than 50 ppm. The PPS resin was dried in a ventilation dryer at a temperature of 115 ° C. to a water content of less than 150 ppm. The PET polymer was heated at 290 ° C. in an extruder and the PPS resin was heated at 295 ° C. in a separate extruder. Two polymers are metered into a spin pack assembly, where the two melt streams are filtered separately and then combined through a bundle of distributor plates to form multiple rows of spunbond fibers having a sheath / core cross section Was provided. Such processes are known to those skilled in the art. The PET component comprised a core and the PPS component comprised a sheath.

  A spin pack assembly composed of 2158 circular capillary openings was heated to 295 ° C. and PPS and PET polymers were spun through each capillary with a polymer extrusion rate of 2.2 g / hole / min. The PET component consisted of 70% by weight of the total weight of the spunbond fibers. The fibers were cooled in a cross flow quench extending over a length of 122 cm. A short slot jet provided damping force to the fiber bundle. The distance from the spin pack to the jet inlet was 147 cm. Fiber exiting the jet was collected on a forming belt moving at 87.4 m / min. The fiber was fixed to the belt by reducing the pressure under the belt. The spunbond layer was then smooth calendered by passing the web between two smooth metals to achieve interfilament bonding. The bonding conditions were a roll temperature of 135 ° C. and a nip pressure of 875 N / cm. After thermal bonding, a spunbond sheet was formed into a roll using a winder.

In an additional step, the nonwoven web was then smooth calendered to achieve further densification of the already bonded nonwoven web. The web was passed between two heated stainless steel rolls having a diameter of 76.2 cm at a nip pressure of 4200 N / cm. The line speed was 61 m / min. The roll was heated to a surface temperature of 200 ° C. After calendering, spunbonded sheets had a basis weight of 51 g / ^{m 2.}

  The results of the tensile test for these samples are shown in the table below. In the table, SnEH is tin (II) ethylhexanoate, ZnO is zinc oxide, SnO is tin oxide, Zn Stearate is zinc stearate, and Sn Stearate is tin stearate. Rate. Using a test piece having a width of 2.54 cm and a gauge length of 18 cm, the tensile strength and break work of the nonwoven sheet were measured with an Instron type tester in accordance with ASTM D 828-97. Only machine direction (MD) results are reported.

  The effect of tin and / or zinc additives in increasing the tensile strength of the web and the total energy to break is apparent from these examples.

Claims (22)

  A nonwoven web comprising bicomponent fibers, the fibers comprising a continuous phase of each of a first polyarylene sulfide (PAS) component and a polymer component, wherein the first polyarylene sulfide component is tin or The web described above containing a zinc additive or both, wherein the first polyarylene sulfide component of any given fiber is at least partially exposed to the outer surface of the fiber.   The web of claim 1, wherein the polymer component comprises a polymer selected from the group consisting of polyetheretherketone (PEEK), polyetherketone (PEK), polyester, polypropylene, polyamide, and mixtures thereof.   The web of claim 2, wherein the polyester comprises polyethylene terephthalate (PET), polytrimethylene terephthalate, or polybutylene terephthalate (PBT).   The web of claim 1 wherein the second polymer component comprises a second polyarylene sulfide.   The web of claim 4 wherein the second polyarylene sulfide is blended with a calcium salt.   The web according to claim 5, wherein the calcium salt is calcium stearate. The tin additive is selected from the group consisting of Sn (O ₂ CR) ₂ , Sn (O ₂ CR) (O ₂ CR ′), Sn (O ₂ CR) (O ₂ CR ″), and mixtures thereof. A branched carboxylate, wherein the carboxylate moieties O ₂ CR and O ₂ CR ′ independently represent a branched carboxylate anion, and the carboxylate moiety O ₂ CR ″ represents a linear carboxylate anion The web of claim 1 representing. The web of claim 7, wherein the tin additive further comprises linear tin (II) carboxylate Sn (O ₂ CR ″) ₂ . The sum of the branched carboxylate moieties O ₂ CR and O ₂ CR ′ is at least about 25, based on moles of all the carboxylate moieties O ₂ CR, O ₂ CR ′ and O ₂ CR ″ contained in the tin additive. The web of claim 7, which is%.   The web according to claim 7, wherein the group R "is a primary alkyl group comprising 6 to 30 carbon atoms.   11. The web of claim 10, wherein the group R "is substituted with a group selected from the group consisting of fluoride, chloride, bromide, iodide, nitro, hydroxyl, carboxylate, and any combination thereof. The radicals R or R ′ are independently or both of formula (I)

[Wherein R ₁ , R ₂ , and R ₃ are
H;
Primary, secondary with 6-18 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups, Or a tertiary alkyl group;
An aromatic group having 6-18 carbon atoms optionally substituted with alkyl, fluoride group, chloride group, bromide group, iodide group, nitro group, hydroxyl group, and carboxyl group; and fluoride Selected from the group consisting of: an alicyclic group having from 6 to 18 carbon atoms optionally substituted with a group, chloride group, bromide group, iodide group, nitro group, hydroxyl group, and carboxyl group;
Provided that when R ₂ and R ₃ are H, R ₁ is:
Secondary or tertiary alkyl having 6 to 18 carbon atoms optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups Group;
An aromatic group having 6 to 18 carbon atoms and substituted with a secondary or tertiary alkyl group having 6 to 18 carbon atoms, the aromatic group and / or the secondary or The tertiary alkyl group may optionally be substituted with a fluoride group, chloride group, bromide group, iodide group, nitro group, hydroxyl group, and carboxyl group, an aromatic group; and optionally a fluoride group, Selected from chloride, bromide, iodide, nitro, hydroxyl, and alicyclic groups having from 6 to 18 carbon atoms that may be substituted with carboxyl groups] The web of claim 7. The web according to claim 7, wherein the groups R or R 'or both have a structure represented by formula (1) and R ₃ is H. The group R or R ′ or both are of the formula (II)

[Where:
R ₄ is a primary, secondary, or tertiary alkyl group having 4 to 6 carbon atoms, optionally fluoride, chloride, bromide, iodide, nitro, And may be substituted with a hydroxyl group; and R ₅ is a methyl, ethyl, n-propyl, sec-propyl, n-butyl, sec-butyl, or tert-butyl group, optionally a fluoride group, chloride Which may be substituted with a product group, bromide group, iodide group, nitro group, and hydroxyl group]
The web of claim 7 having a structure represented by: The groups R and R 'are the same, both have the structure represented by formula (II), R ₄ is n-butyl, and R ₅ is ethyl. web.   The web of claim 1 wherein the tin additive is present at a concentration of about 10 weight percent or less of the weight of the first polyarylene sulfide component.   The web of claim 1, wherein the zinc additive is selected from the group consisting of one zinc (II) additive, zinc metal [Zn (0)], or both.   The web of claim 17, wherein the zinc (II) additive is an organic compound or an inorganic compound or a mixture of both.   19. The web of claim 18, wherein the zinc (II) additive is selected from the group consisting of zinc oxide, zinc stearate, zinc sulfate and mixtures thereof.   The web of claim 1, wherein the zinc and tin additives are present at a total concentration of about 25 weight percent or less, based on the weight of the polyarylene sulfide.   21. The web of claim 20, wherein the zinc additive is present at a concentration of 0 to about 10 weight percent, based on the weight of the polyarylene sulfide.   The web of claim 4 wherein the first polyarylene sulfide or the second polyarylene sulfide or both are polyphenylene sulfide.