JP2015089972A - Nonwoven fabric and textile product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a nonwoven fabric and a textile product that can maintain high strength under a high temperature, have high rigidity, and are excellent in formability.SOLUTION: The nonwoven fabric can be obtained by using a binder fiber and a polycarbonate fiber having a single fiber diameter of 5-50 μm and a tensile strength of 1.5 cN/dtex or greater, in which the content of the polycarbonate fiber is 10-80 mass% relative to the weight of the nonwoven fabric.

Description

  The present invention relates to a nonwoven fabric and a textile product that maintain high strength even at high temperatures, have high rigidity, and are excellent in moldability.

So far, non-woven fabrics have been studied and adapted for various uses. For example, an aramid fiber is used if heat resistance is required, and a glass fiber or carbon fiber is used as a matrix fiber if rigidity is required.
Under such circumstances, polycarbonate resins, which are engineering plastics adapted to various resin moldings and optical applications, have been studied for fiberization and non-woven fabrics using them, but the physical properties have not yet been satisfactory.

For example, in a case where a polycarbonate resin is made into a sheet by the melt blow method and subjected to electret processing (Patent Document 1), the fineness becomes small, and it is difficult to obtain the rigidity necessary for the filter application.
In addition, the one using a split type composite fiber composed of a polycarbonate resin and other components (Patent Document 2) requires a splitting process in the nonwoven fabric manufacturing process, and uses that can be developed are extremely limited. There was concern.

JP-A-10-245772 JP 2009-84737 A

  The present invention has been made in view of the above background, and an object of the present invention is to provide a nonwoven fabric and a fiber product that maintain high strength even at high temperatures, have high rigidity, and are excellent in moldability.

  As a result of intensive studies to achieve the above-mentioned problems, the present inventors have found that when a nonwoven fabric is formed using a binder fiber and a polycarbonate fiber having specific physical properties, it maintains high strength even at high temperatures and has high rigidity. The present inventors have found that a non-woven fabric excellent in moldability can be obtained, and have completed the present invention by further intensive studies.

  Thus, according to the present invention, “a binder fiber and a polycarbonate fiber having a single fiber diameter of 5 to 50 μm and a tensile strength of 1.5 cN / dtex or more, and the content of the polycarbonate fiber is 10 with respect to the weight of the nonwoven fabric. A non-woven fabric characterized in that it is ˜80% by weight. ”

  In that case, it is preferable that the said binder fiber is a core-sheath-type binder fiber. In the core-sheath binder fiber, the sheath component preferably has a melting point or softening point of 160 ° C. or lower. In the core-sheath binder fiber, the core component is preferably made of polyester. The binder fiber preferably has a single fiber diameter in the range of 5 to 50 μm. In the polycarbonate fiber, the birefringence Δn is preferably 0.03 or more. The polycarbonate fiber preferably has a tensile elongation of 60% or less.

In the nonwoven fabric of the present invention, the nonwoven fabric is preferably any nonwoven fabric selected from the group consisting of a dry nonwoven fabric, a three-dimensional fiber structure, a wet nonwoven fabric, and an airlaid nonwoven fabric.
Moreover, according to the present invention, the filter, separator, vehicle material, molded body, cushioning material, sound absorbing material, life material, electrical material, building material, civil engineering material, agricultural material, and abrasive material comprising the above-mentioned nonwoven fabric are used. A textile product selected from the group is provided.

  ADVANTAGE OF THE INVENTION According to this invention, while maintaining high intensity | strength also under high temperature, it has a high rigidity, and the nonwoven fabric and textiles which were excellent also in the moldability are provided.

First, the “polycarbonate fiber” in the present invention means a fibrous material in which the junction between monomer units is composed of a carbonate group.
In the polycarbonate fiber, it is important that the single fiber diameter is in the range of 5 to 50 μm (more preferably 15 to 30 μm). If the diameter of the single fiber is less than 5 μm, spots are likely to be produced at the time of fiber production. As a result, spots of the nonwoven fabric are generated, and it is difficult to uniformly disperse even in the nonwoven fabric process. On the contrary, if the single fiber diameter exceeds 50 μm, the number of fibers occupied in the nonwoven fabric is reduced, the uniformity is insufficient, and the adhesion point may be reduced.

  The polycarbonate fiber preferably has a tensile strength of 1.5 cN / dtex or more (more preferably 1.7 to 6.0 cN / dtex). When the tensile strength is less than 1.5 cN / dtex, the fiber is often soft and is not preferable as an aggregate fiber exhibiting rigidity and heat resistance.

The polycarbonate fiber preferably has a tensile elongation of 60% or less. If the tensile elongation exceeds 60%, the fibers are soft and the comrades tend to be entangled with each other, which may reduce the rigidity of the entire nonwoven fabric.
In the polycarbonate fiber, the birefringence Δn is preferably 0.03 or more (more preferably 0.04 to 0.06). When the birefringence Δn is less than 0.03, the polycarbonate fiber itself is deformed during heat treatment, and it may be difficult to exhibit the rigidity and heat resistance of the nonwoven fabric.

Although the unstretched fiber may be sufficient as a binder fiber in this invention, a core-sheath-type binder fiber (core-sheath-type composite fiber) is preferable. As such a sheath-core type binder fiber, a polymer having a melting point lower by 40 ° C. or more than the polymer forming the main fiber is arranged on the surface as a heat fusion component.
Here, examples of the polymer arranged as the heat-fusion component include polyurethane elastomers, polyester elastomers, inelastic polyester polymers and copolymers thereof, polyolefin polymers and copolymers thereof, polyvinyl alcohol polymers, and the like. be able to.

  Among these, polyurethane elastomers include low melting point polyols having a molecular weight of about 500 to 6,000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and organic diisocyanates having a molecular weight of 500 or less, such as p, p. '-Diphenyl methane diisocyanate, tolylene diisocyanate, isophorone diisocyanate hydrogenated diphenyl methane isocyanate, xylylene isocyanate, 2,6-diisocyanate methyl caproate, hexamethylene diisocyanate and the like, and chain extenders having a molecular weight of 500 or less, such as glycol It is a polymer obtained by reaction with amino alcohol or triol.

  Among these polymers, particularly preferred is a polyurethane using polytetramethylene glycol, poly-ε-caprolactam or polybutylene adipate as a polyol. Examples of the organic diisocyanate in this case include p, p'-bishydroxyethoxybenzene and 1,4-butanediol.

  Polyester elastomers include polyether ester copolymers obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, and more specifically, terephthalic acid, isophthalic acid, phthalate. Alicyclic dicarboxylic acids such as acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid , At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as adipic acid, sebacic acid, dodecanedioic acid and dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol , Tetramethylene glycol Aliphatic diols such as pentamethylene glycol, hexamethylene glycol neopentyl glycol, decamethylene glycol, or alicyclic diols such as 1,1-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, tricyclodecane methanol, or the like At least one diol component selected from ester-forming derivatives and the like, and polyethylene glycol, poly (1,2- and 1,3-polypropylene oxide) glycol having an average molecular weight of about 400 to 5,000, poly (tetra Methylene oxide) glycol, ethylene oxide / propylene oxide copolymer, ethylene oxide / tetrahydrofuran copolymer, etc. It can be mentioned terpolymer that.

  In particular, from the viewpoint of adhesiveness, temperature characteristics, and strength, block copolymer polyether esters having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment are preferable. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component. Of course, a part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or an oxycarboxylic acid component, and similarly a part of the glycol component (usually 30 mol% or less). May be substituted with a dioxy component other than the butylene glycol component. Further, the polyether portion constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol.

Copolyester polymers include aliphatic dicarboxylic acids such as adipic acid and sebacic acid, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid and naphthalenedicarboxylic acid and / or fats such as hexahydroterephthalic acid and hexahydroisophthalic acid. A co-polymer containing a predetermined number of cyclic dicarboxylic acids and aliphatic or alicyclic diols such as diethylene glycol, polyethylene glycol, propylene glycol, and paraxylene glycol, with addition of oxyacids such as parahydroxybenzoic acid as desired. Polymerized esters and the like can be mentioned. For example, polyesters obtained by adding and copolymerizing isophthalic acid and 1,6-hexanediol in terephthalic acid and ethylene glycol can be used.
Examples of the polyolefin-based polymer include low-density polyethylene, high-density polyethylene, polypropylene, and modified products thereof.

In the core-sheath-type binder fiber, a polyester as described below is preferably exemplified as the counterpart component of the heat fusion component. In that case, it is preferable that the heat fusion component occupies at least a half of the surface area. The weight ratio is suitably in the range of 30/70 to 70/30 in terms of the composite ratio of the heat fusion component and the polyester. Although it does not specifically limit as a form of a core-sheath-type binder fiber, It is important that a heat-fusion component and polyester are core-sheath types. In this core-sheath-type binder fiber, polyester serves as a core part and the heat fusion component serves as a sheath part, but this core part may be concentric or eccentric. From the viewpoint of adhesion to the main fiber and processability (dispersibility, etc.) in the papermaking process, it is more preferable to dispose polyester in the core and dispose low-melting polyester in the sheath.
In the above-described polymer, various stabilizers, ultraviolet absorbers, thickening and branching agents, matting agents, coloring materials, and various other improving agents may be blended as necessary.

  In the binder fiber, the single fiber diameter is preferably in the range of 5 to 50 μm (more preferably 20 to 30 μm). If the fiber diameter is less than 5 μm, it may be difficult to form a fixing point. On the other hand, when the fiber diameter is larger than 50 μm, the processability such as the card process in producing the fiber structure may be unstable.

In the non-woven fabric of the present invention, the non-woven fabric may be composed of the polycarbonate fiber and the binder fiber, and a matrix fiber other than the polycarbonate fiber (hereinafter sometimes simply referred to as “matrix fiber”) is further included. May be.
As the matrix fibers other than the polycarbonate fibers, natural fibers, synthetic fibers (including semi-synthetic fibers) and the like can be used. In particular, synthetic fibers are preferable. Among them, thermoplastic fibers such as aromatic polyamide fibers or polyester fibers are preferable.

  The “aromatic polyamide fiber” as used herein means a fibrous material composed of a linear polymer compound in which 60% or more, preferably 85% or more of amide bonds are directly bonded to an aromatic ring. Such an aromatic polyamide fiber is not particularly limited. For example, polymetaphenylene isophthalamide fiber (manufactured by Teijin Ltd., trade name Conex), polyparaphenylene terephthalamide fiber (manufactured by Teijin Aramid Corporation, trade name Twaron), Examples include poly (paraphenylene) -copoly (3,4-diphenyl ether) terephthalamide fiber (manufactured by Teijin Limited, trade name Technora).

  Examples of the polyester fiber include polyesters such as polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polylactic acid, and stereocomplex polylactic acid, and a copolymerized polyester obtained by copolymerizing a third component. Examples of such polyester include material-recycled or chemical-recycled polyester, and polyethylene terephthalate using a monomer component obtained by using biomass, that is, a biological material as a raw material, described in JP-A-2009-091694. May be. Furthermore, the polyester obtained using the catalyst containing the specific phosphorus compound and titanium compound which are described in Unexamined-Japanese-Patent No. 2004-270097 and 2004-21268 may be sufficient. In the polymer, a fine pore forming agent, a cationic dye dyeing agent, an anti-coloring agent, a heat stabilizer, a fluorescent whitening agent, a matting agent, a coloring agent may be added as necessary within the range not impairing the object of the present invention. 1 type (s) or 2 or more types of an agent, a hygroscopic agent, and inorganic fine particles may be contained.

  In the matrix fiber, one or more agents selected from the group consisting of silicone resin, oil agent, antibacterial agent, insect repellent agent, water repellent agent, hygroscopic agent, antistatic agent, flame retardant, negative ion generator and deodorant. Is adhering to the fiber surface, it is preferable that these agents do not easily fall off, so that the functions of these agents can be expressed with good durability. The oil agent includes a smoothing agent such as fatty acid ester, polyhydric alcohol ester, ether ester, polyether, silicone, mineral oil, antistatic agent, surfactant, bundling agent, rust inhibitor, preservative, and antioxidant. An agent may be added.

  The fiber diameter of the matrix fiber is preferably 5 to 50 μm (more preferably 20 to 30 μm). If it is less than 5 micrometers, it will be easy to produce the entanglement of the fibers in a nonwoven fabric process, and there exists a possibility of becoming a textured spot. Conversely, if it exceeds 50 μm, mixing with other fibers may be difficult.

  It is important that the ratio of the polycarbonate fiber contained in the nonwoven fabric of the present invention is in the range of 10 to 80% by weight (more preferably 30 to 60%) relative to the weight of the nonwoven fabric. If the ratio is less than 10% by weight, the ratio of the polycarbonate fiber in the nonwoven fabric is too small, and the strength and rigidity of the nonwoven fabric may be reduced. On the other hand, if the ratio exceeds 80% by weight, the fibers are rigid and the entanglement between the fibers is insufficient, so that the connection between the fibers is low and stable production may be difficult.

Moreover, as a weight with respect to the whole nonwoven fabric of a binder fiber, it is preferable to exist in the range of 20 to 70 weight% (preferably 30 to 50 weight%). If the ratio is less than 20% by weight, the adhesion point may be absolutely insufficient. On the other hand, when the ratio exceeds 70% by weight, there are too many adhesion points due to the binder fibers, which may make it difficult to control the density.
Moreover, it is preferable that matrix fibers other than the said polycarbonate fiber are 0-50 weight% (preferably 0-30 weight%) with respect to a nonwoven fabric weight.

The non-woven fabric of the present invention is a dry method (card method) in which fibers are opened and mixed using a roller with needles, and a relatively short fiber is dispersed in water, and a wet method (paper making) Method), after a web is formed by an airlaid method (airlaid method, dry pulp method) or the like in which a relatively short fiber is sent to a perforated drum by air and dispersed by air and then deposited on a wire to obtain a sheet. The structure by the entanglement and / or heat treatment process is fixed. In addition, among dry nonwoven fabrics and thermal bond nonwoven fabrics, those having a low density (0.01 to 0.10 g / cm ³ ) are being developed for applications characterized by resilience, cushioning properties, etc. Sometimes referred to as a fiber structure (sometimes simply referred to as a “fiber structure”) or hard cotton.
Since the optimum conditions differ depending on the nonwoven fabric manufacturing method, each will be described separately.

<Dry method>
As a feature of the dry nonwoven fabric, it is possible to produce a wide range from a low basis weight to a high basis weight. If the nonwoven fabric of the present invention to adapt the dry method, the basis weight is preferably in the range of 15~2000g / ^{m 2,} and still more preferably is in the range of from 20~1200g / ^{m 2.} If the basis weight is less than 15 g / m ² , it may be extremely difficult to continuously produce a uniform web. On the other hand, when the basis weight exceeds 2000 g / m ² , productivity may be deteriorated.
Fiber fixing methods include entanglement of fibers by needle (needle punch method), entanglement of fibers by high-pressure water flow (spun lace method), adhesion by binder fiber (air-through method), entanglement by shrinkage, press by hot roll Etc. can be used as appropriate.

When the nonwoven fabric of the present invention is a dry nonwoven fabric, the fiber length is preferably in the range of 30 to 150 mm, and more preferably in the range of 50 to 100 mm. If the fiber length is less than 30 mm, the web connection at the time of fiber opening is weak and there is a possibility that the occurrence of fiber dropout will increase. On the contrary, if the fiber length exceeds 150 mm, entanglement tends to occur and there is a risk that nep and the like are likely to occur.
When the dry method is applied to the nonwoven fabric of the present invention, it is preferable that crimps are imparted to the polycarbonate fibers, matrix fibers, and binder fibers used. At that time, as a method for imparting crimp, indentation crimp, gear crimp, three-dimensional crimp using anisotropy at the time of spinning, or the like can be used as appropriate.

<Three-dimensional fiber structure (hard cotton)>
As a feature of the three-dimensional fiber structure, it can be used for a cushion material, a sound absorbing material, a heat insulating material, etc. at a relatively low density.
When the nonwoven fabric of the present invention is a three-dimensional fiber structure, the density is preferably within a range of 0.01 to 0.10 g / cm ³ , and within a range of 0.02 to 0.08 g / cm ^3. Is more preferable. If the density is less than 0.01 g / cm ³ , there are many voids and there is a distance between the fibers, which may make it difficult to form an adhesion point. On the other hand, if the density exceeds 0.10 g / cm ³ , it is difficult to crush the web, and the productivity and stability may be lacking.
When the nonwoven fabric of this invention is a three-dimensional fiber structure, it is preferable that crimp is provided to the polycarbonate fiber, matrix fiber, and binder fiber to be used. As a method for imparting crimps, indentation crimps, gear crimps, three-dimensional crimps using anisotropy during spinning, and the like can be used as appropriate.

<Wet method>
The characteristics of the wet method nonwoven fabric are that the formation is very good, a low-weight nonwoven fabric of several grams can be made, and the productivity is high.
If the nonwoven fabric is wet-laid nonwoven fabric of the present invention, the basis weight is preferably in the range of 5 to 200 g / ^{m 2,} and more preferably in a range of 20 to 100 g / ^{m 2.} If the basis weight is less than 5 g / m ² , it may be extremely difficult to produce. On the contrary, when the basis weight exceeds 200 g / m ² , the productivity of the nonwoven fabric may be deteriorated.
When the nonwoven fabric of the present invention is a wet nonwoven fabric, the fiber length is preferably in the range of 2 to 25 mm, and more preferably in the range of 3 to 20 mm. If the fiber length is less than 2 mm, there is little entanglement between the fibers, and the strength of the nonwoven fabric may be difficult. Conversely, if the fiber length exceeds 25 mm, uniform dispersion may be extremely difficult.

When the nonwoven fabric of the present invention is a wet nonwoven fabric, the polycarbonate fiber, binder fiber, and matrix fiber to be used are not particularly limited in terms of imparting crimps. It is preferable to have a three-dimensional crimp, and when the bulk is unnecessary, a straight fiber having no crimp is preferable.
When the non-woven fabric of the present invention is a wet non-woven fabric, the production method is roughly divided into a “paper making process” and a “heat treatment process”. As the paper making process, a short net paper machine, a circular net paper machine, or the like can be used. As the heat treatment step, a rotary dryer, a multi-cylinder dryer, a calendar, etc. can be used alone or in combination depending on the use situation. Further, as post-processing, various types of resin processing and fiber entanglement processing by high-pressure water flow may be performed.

<Airlaid nonwoven fabric>
A feature of the airlaid nonwoven fabric is that it has a structure close to that of a wet nonwoven fabric and can have a low density (bulky) structure.
If the nonwoven fabric is air-laid nonwoven fabric of the present invention, the basis weight is preferably in the range of 10 to 400 g / ^{m 2,} and more preferably in a range of 20 to 300 g / ^{m 2.} If the basis weight is less than 10 g / m ² , it may be extremely difficult to produce. Conversely, if the basis weight exceeds 400 g / m ² , the productivity of the nonwoven fabric may be deteriorated.

  When the nonwoven fabric of the present invention is an airlaid nonwoven fabric, the fiber length of the polycarbonate fiber, matrix fiber, and binder fiber used is preferably in the range of 2 to 15 mm, and more preferably in the range of 3 to 7 mm. If the fiber length is less than 2 mm, there is little entanglement between the fibers, and the strength of the nonwoven fabric may be difficult. Conversely, if the fiber length exceeds 15 mm, uniform dispersion may be extremely difficult.

  When the nonwoven fabric of the present invention is an air-laid nonwoven fabric, the polycarbonate fiber, binder fiber, and matrix fiber to be used are not particularly limited in terms of crimping, but in order to increase dispersibility and bulk, a zigzag-shaped mechanical cage is used. It is preferable to have a crimp or a spiral three-dimensional crimp, and when the bulk is unnecessary, a straight fiber having no crimp is preferable.

  The method for producing an air laid nonwoven fabric is roughly divided into a “web forming step” and a “heat treatment step”. As the web forming step, a method of forming by centrifugal force and suction by the rotation of two perforated drums (sometimes referred to as a head) (dan web method) is preferably used. In addition, the nonwoven fabric which piled up the layer from which a raw cotton structure differs can be manufactured directly by arranging many heads in series. As the heat treatment step, hot air suction type treatment, calendering, embossing and the like can be used alone or in combination depending on the use situation. Further, as post-processing, various types of resin processing and fiber entanglement processing by high-pressure water flow may be performed.

Next, the textile product of the present invention comprises the above-described nonwoven fabric, filter, separator, vehicle material, molded body, cushion material, sound absorbing material, life material, electrical material, building material, civil engineering material, agricultural material, and polishing. A textile product selected from the group consisting of materials.
Since such a fiber product uses the above-mentioned nonwoven fabric, it maintains high strength even at high temperatures, has high rigidity, and is excellent in moldability.

  Next, although the Example and comparative example of this invention are explained in full detail, this invention is not limited by these. In addition, each measurement item in an Example was measured with the following method.

(1) Birefringence Δn
Measurement was carried out based on JIS K0062 (Method of measuring refractive index of chemical product). However, 1-bromonaphthalene (refractive index n _D ²⁰ 1.6576) was used as an intermediate solution.

(2) Weight per unit area Calculated according to the following formula according to JIS L1906.
Weight per unit area (g / m ² ) = weight (g) / nonwoven fabric area (m ² )

(3) Thickness of the nonwoven fabric It was measured using a thickness meter (peacock type).

(4) Density Calculated by the following formula.
Bulk density (g / cm ³ ) = basis weight / thickness

(5) Tensile strength and tensile elongation of fiber Measured according to JIS L1013 7.5.

(6) Number of crimps and crimp rate Measured by the method described in JIS L 1015. In addition, the average value was calculated | required by n number 5.

(7) Tensile strength of nonwoven fabric A test piece having a width of 50 mm was measured with a constant elongation type tensile tester (Instron) at a measurement length of 10 mm.

(8) Heat resistance In the tensile strength of the preceding clause, the measurement environment was implemented under 100 degreeC, and the heat resistance (strength retention rate) was computed by the following formula with the change rate.
Heat resistance = tensile strength at 100 ° C./tensile strength at room temperature × 100

(9) Rigidity Measured by JIS L1096 6.19 45 ° cantilever method (width 2 cm).

(Sample-1)
A polycarbonate chip (trade name Panlite L-1225L, manufactured by Teijin Limited) was dried at 130 ° C. for 8 hours. This was spun from a spinneret at a polymer melting temperature of 290 ° C. and stored in a tow can, and then stretched and tensioned and heat set by a conventional method to obtain a polycarbonate long fiber (single fiber diameter: 12 μm (1.7 dtex ), Tensile strength 3.5 cN / dt, tensile elongation 35%, birefringence (Δn) 0.048). Then, the cut length and finishing oil based on each manufacturing method were provided, and the polycarbonate short fiber was obtained.
For dry type: Fiber length 51mm, Number of crimps 11.5 / 2.54cm, Crimp rate 22.0%
For three-dimensional fiber structure: fiber length 51 mm, number of crimps 11.5 / 2.54 cm, crimp rate 22.0%
For wet use: Fiber length 5 mm, No crimp Airlaid: Fiber length 5 mm, Crimp number 8.5 pieces / 2.54 cm, Crimp rate 15.4%

<Dry method>
[Example 1]
Polycarbonate short fibers prepared in Sample-1, polyethylene terephthalate short fibers (single fiber diameter 12 μm (1.7 dtex), fiber length 51 mm) as other matrix fibers, and core-sheath composite binder fibers (core: polyester, Sheath: Low melting point polyester, single fiber diameter 12 μm (1.7 dtex), fiber length 51 mm) was opened with a roller card at this ratio of 50/20/30, and then entangled with a needle punch machine Thereafter, heat treatment (150 ° C. × 5 minutes) was performed to obtain a nonwoven fabric. Table 1 shows the physical properties of the obtained nonwoven fabric.

[Example 2]
In Example 1, the nonwoven fabric was obtained by the same method except changing the ratio from 50/20/30 to 15/55/30. Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 1]
In Example 1, the nonwoven fabric was obtained by the same method except having changed the ratio into 0/70/30 (a polycarbonate fiber is not used). Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 2]
In Example 1, a nonwoven fabric was obtained in the same manner except that the ratio was 85/0/15. Table 1 shows the physical properties of the obtained nonwoven fabric.

<Three-dimensional fiber structure>
[Example 3]
Polycarbonate short fibers prepared in Sample-1, polyethylene terephthalate short fibers (fiber diameter 12 μm (1.7 dtex), fiber length 51 mm) as other matrix fibers, and core-sheath composite binder fibers (core: polyester, sheath: After opening a low melting polyester, single fiber diameter 12 μm (1.7 dtex), fiber length 51 mm) with a roller card at a ratio of 50/20/30, the density is 0.035 g / cm ³ using a mold. Then, after adjusting the thickness, hot air treatment (170 ° C. × 15 minutes) was performed to obtain a three-dimensional fiber structure. Table 1 shows the physical properties of the obtained three-dimensional fiber structure.

[Example 4]
In Example 3, the nonwoven fabric was obtained by the same method except having changed the ratio from 50/20/30 to 15/55/30. Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 3]
In Example 3, a nonwoven fabric was obtained in the same manner except that the ratio was changed to 0/70/30 (no polycarbonate fiber was used). Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 4]
In Example 3, a nonwoven fabric was obtained in the same manner except that the ratio was 85/0/15. Table 1 shows the physical properties of the obtained nonwoven fabric.

<Wet method>
[Example 5]
Polycarbonate short fiber prepared in Sample-1, polyester fiber (single fiber diameter 12 μm, fiber length 5 mm, no crimp), core-sheath composite binder fiber (core: polyester, sheath: low melting point polyester, fiber length 12 μm) as binder fiber (1.7 dtex), fiber length 5 mm, no crimp) was weighed at a weight ratio of 50/20/30, and then the fibers were poured into water so that the fiber concentration was 0.2% and stirred with a mixer. Thereafter, a wet paper having a basis weight of 50 g / m ² was obtained using TAPPI. The obtained wet paper was processed with a rotary dryer at 130 ° C. for 1 minute to obtain a wet nonwoven fabric. Table 1 shows the physical properties of the obtained nonwoven fabric.

[Example 6]
In Example 5, the nonwoven fabric was obtained by the same method except changing the ratio from 50/20/30 to 5/65/30. Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 5]
In Example 5, a non-woven fabric was obtained in the same manner except that the ratio was changed to 0/70/30 (no polycarbonate fiber was used). Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 6]
In Example 5, a nonwoven fabric was obtained in the same manner except that the ratio was 85/0/15. Table 1 shows the physical properties of the obtained nonwoven fabric.

<Airlaid method>
[Example 7]
Polycarbonate short fiber prepared in Sample-1 and core-sheath composite binder fiber (core: polyester, sheath: low melting point polyester, single fiber diameter: 12 μm (1.7 dtex), fiber length: 5 mm, crimp number: 8.5 /2.54 cm, crimp rate 14%) at a ratio of 30/70, and after forming a web using the airlaid nonwoven fabric manufacturing facility described in Japanese Patent No. 3880456, using a hot-air suction dryer To obtain a nonwoven fabric. Table 1 shows the physical properties of the obtained nonwoven fabric.

[Example 8]
In Example 7, the nonwoven fabric was obtained by the same method except changing the ratio to 70/30. Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 7]
In Example 7, a nonwoven fabric was obtained in the same manner except that the ratio was changed to 0/100 (no polycarbonate fiber was used). Table 1 shows the physical properties of the obtained nonwoven fabric.

[Comparative Example 8]
In Example 7, it replaces with a polycarbonate short fiber, and it is the same except changing to a polyester fiber (single fiber diameter 12 micrometers, fiber length 5mm, the number of crimps 7.5 / 2.54cm, a crimp rate of 14%). The nonwoven fabric was obtained by the method. Table 1 shows the physical properties of the obtained nonwoven fabric.

  ADVANTAGE OF THE INVENTION According to this invention, while maintaining high intensity | strength also under high temperature, it has a high rigidity, and the nonwoven fabric and textiles which were excellent also in the moldability are provided, The industrial value is very large.

Claims (9)

  It contains a binder fiber and a polycarbonate fiber having a single fiber diameter of 5 to 50 μm and a tensile strength of 1.5 cN / dtex or more, and the content of the polycarbonate fiber is 10 to 80% by weight based on the weight of the nonwoven fabric. Characteristic nonwoven fabric.   The nonwoven fabric according to claim 1, wherein the binder fiber is a core-sheath type binder fiber.   The nonwoven fabric according to claim 2, wherein in the core-sheath binder fiber, the melting point or softening point of the sheath component is 160 ° C or lower.   The nonwoven fabric according to claim 2 or 3, wherein the core-sheath binder fiber comprises a polyester as a core component.   The nonwoven fabric in any one of Claims 1-4 whose single fiber diameter exists in the range of 5-50 micrometers in the said binder fiber.   The nonwoven fabric according to any one of claims 1 to 5, wherein the polycarbonate fiber has a birefringence Δn of 0.03 or more.   The nonwoven fabric according to any one of claims 1 to 6, wherein the polycarbonate fiber has a tensile elongation of 60% or less.   The nonwoven fabric according to any one of claims 1 to 7, wherein the nonwoven fabric is any nonwoven fabric selected from the group consisting of a dry nonwoven fabric, a three-dimensional fiber structure, a wet nonwoven fabric, and an airlaid nonwoven fabric.   A filter, a separator, a vehicle material, a molded body, a cushioning material, a sound absorbing material, a living material, an electrical material, a building material, a civil engineering material, an agricultural material, and an abrasive material, comprising the nonwoven fabric according to any one of claims 1 to 8. A textile product selected from the group consisting of: