JP2017226928A - Heat-resistant wet type nonwoven fabric - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heat-resistant nonwoven fabric in which paper breakage is difficult to occur when producing the heat-resistant wet type nonwoven fabric according to a wet type paper-making method, in the heat-resistant wet nonwoven fabric containing a PPS fiber.SOLUTION: A heat-resistant wet type nonwoven fabric is characterized so as to contain a drawn polyphenylene sulfide fiber and, the drawn polyphenylene sulfide fiber and a core-sheath type polyester composite fiber in the heat-resistant wet type nonwoven fabric containing the polyphenylene sulfide fiber.SELECTED DRAWING: None

Description

  The present invention relates to a heat-resistant wet nonwoven fabric containing polyphenylene sulfide fibers.

  Polyphenylene sulfide (PPS) fiber is a high-performance fiber with excellent heat resistance, chemical resistance, hydrolysis resistance, dimensional stability during moisture absorption, insulation, flame retardancy, and heat retention, so its use is expanding doing. For example, filters for collecting high-temperature gas dust, canvas for dryers used in the drying process of industrial products, roll wiping materials for office copiers, insulating materials for electrical equipment, cushioning materials (cushion materials), heat insulation cloths, batteries Uses such as a separator can be mentioned.

  As a heat resistant nonwoven fabric containing PPS fibers, a heat resistant wet nonwoven fabric manufactured by a wet papermaking method is known. For example, a heat-resistant wet nonwoven fabric using a stretched PPS fiber and an unstretched PPS fiber is known (see, for example, Patent Documents 1 and 2). In the case of producing a wet nonwoven fabric by the wet papermaking method, there are a wet press section for squeezing water from a wet paper produced by a papermaking net, a step of conveying the wet paper to a dryer, and the like. In the heat-resistant wet nonwoven fabric containing stretched PPS fibers and unstretched PPS fibers, there has been a problem that paper breakage is likely to occur in the wet press section and the transport process.

JP 2010-24574 A JP 2011-106043 A

  The subject of this invention is providing the heat resistant nonwoven fabric which is hard to generate | occur | produce a paper break when manufacturing a heat resistant wet nonwoven fabric by the wet papermaking method in the heat resistant wet nonwoven fabric containing PPS fiber.

  The above problems can be solved by the following invention.

(1) A heat-resistant wet nonwoven fabric containing polyphenylene sulfide fibers, comprising stretched polyphenylene sulfide fibers, unstretched polyphenylene sulfide fibers, and core-sheath type polyester composite fibers.

(2) The heat-resistant wet nonwoven fabric according to (1), wherein the content ratio of the core-sheath polyester composite fiber is 3% by mass or more and 30% by mass or less.

  ADVANTAGE OF THE INVENTION According to this invention, in the heat resistant wet nonwoven fabric containing a PPS fiber, when manufacturing a heat resistant wet nonwoven fabric with a wet papermaking method, the heat resistant nonwoven fabric which cannot produce a paper break easily can be provided.

  The heat-resistant wet nonwoven fabric of the present invention is a heat-resistant wet nonwoven fabric containing stretched PPS fibers, unstretched PPS fibers, and core-sheath polyester composite fibers.

A polyphenylene sulfide (Polyphenylene sulfide) fiber is a synthetic fiber made of a polymer (PPS polymer) having — (C ₆ H ₄ —S) — as a polymer structural unit as a main structural unit. Representative examples of the PPS polymer include polyphenylene sulfide, polyphenylene sulfide sulfone, polyphenylene sulfide ketone and the like. Moreover, these random copolymers, block copolymers, etc. are also mentioned. Furthermore, the mixture of the said polymer is mentioned. As a particularly preferred PPS polymer, polyphenylene sulfide containing preferably 90% by mass or more of a p-phenylene unit represented by — (C ₆ H ₄ —S) — is mentioned as the main structural unit of the polymer.

  In the present invention, unstretched PPS fibers and stretched PPS fibers are used as the PPS fibers. The unstretched PPS fibers are mostly non-crystalline structures and can be melted by applying heat to act as a binder. The drawn PPS fiber is stretched in the fiber production process, so that the single fiber strength of the fiber is strong and the dimensional stability is excellent. In this invention, the nonwoven fabric excellent in heat resistance and insulation can be provided by using an unstretched PPS fiber and a stretched PPS fiber together.

  Considering the production efficiency in the wet papermaking method, the fiber length of the PPS fiber is preferably 1 to 30 mm, more preferably 3 to 12 mm. Further, the fiber diameter of the PPS fiber is preferably 30 μm or less, more preferably 25 μm or less, and further preferably 20 μm or less. The lower limit of the fiber diameter is preferably 0.1 μm or more.

  The core-sheath type polyester composite fiber is a fiber made of a combination of a high melting point polyester (core) and a low melting point polyester (sheath). The sheath is preferably a copolyester. Copolyester includes a terephthalic acid component and an ethylene glycol component, and an isophthalic acid component, adipic acid component, sebacic acid component, naphthalenedicarboxylic acid component, diethyl glycol component, 1,4-butanediol component and aliphatic Examples thereof include a copolyester containing at least one component selected from the group of lactone components. This copolyester may be amorphous or crystalline. The core is preferably a polyester whose main repeating unit is alkylene terephthalate, and is preferably polyethylene terephthalate having high heat resistance.

  In the present invention, the cross-sectional shape of the core-sheath polyester composite fiber is not particularly limited, but is preferably circular. Further, the ratio of the core part to the sheath part is preferably in the range of core / sheath = 30/70 to 70/30, more preferably 40/60 to 60/40, in terms of volume ratio.

  When stretched PPS and unstretched PPS fibers are made into a sheet by the wet papermaking method, the water retention in the wet paper state is extremely low, so the paper breaks in the process of transporting to the wet press section or dryer of the paper machine There was a problem that was likely to occur. The fibers used in the present invention are stretched PPS fibers, unstretched PPS fibers, and core-sheath polyester composite fibers. By using a slurry in which these fibers are dispersed in water, a heat-resistant wet nonwoven fabric is produced by a wet papermaking method. In doing so, the effect of fewer paper breaks can be obtained. More specifically, by using the core-sheath polyester composite fiber, the stretched PPS fiber, and the unstretched PPS fiber in combination, the core-sheath polyester composite fiber and the PPS fiber are intertwined well in the slurry, and the wet paper web strength is strong. As a result, fiber peeling and paper breakage are less likely to occur in the wet press section of the paper machine. Furthermore, by increasing the water retention of the wet paper, it can be smoothly transported to the dryer and paper breakage can be suppressed. In addition, after drying, the strength of the heat-resistant wet nonwoven fabric can be increased in order that the sheath portion of the core-sheath polyester composite fiber can efficiently bond the intersection of the stretched PPS fiber and the unstretched PPS fiber.

  The fiber diameter of the core-sheath polyester composite fiber is preferably 1 μm to 20 μm, more preferably 2 to 17 μm, and still more preferably 5 to 15 μm. If it is less than 1 μm, it may fall off the papermaking net of the wet papermaking machine. On the other hand, if it exceeds 20 μm, the degree of entanglement between the PPS fiber and the core-sheath polyester composite fiber in the slurry becomes insufficient, and the effect of suppressing paper breakage in the wet papermaking process is not sufficient, and the contact between fibers is not sufficient. In some cases, it becomes too small to maintain the strength.

  The fiber length of the core-sheath polyester composite fiber is preferably 1 to 20 mm, more preferably 2 to 15 mm, and still more preferably 3 to 10 mm. If it is less than 1 mm, it may fall off the papermaking wire during wet papermaking, and sufficient strength may not be obtained. On the other hand, when it exceeds 20 mm, it may cause entanglement or the like when dispersed in water, and a uniform formation may not be obtained.

  30-70 mass% is preferable with respect to the heat-resistant wet nonwoven fabric of this invention, 30-70 mass% is more preferable, 35-65 mass% is more preferable, and 40-60 mass% is still more preferable. Within the above range, the heat resistance can be enhanced by the drawn PPS fiber. When the content of the drawn PPS fiber is less than 30% by mass, the heat resistance may be insufficient. Moreover, when it exceeds 70 mass%, there exists a possibility that the intensity | strength of a heat resistant wet nonwoven fabric may be insufficient.

  20-60 mass% is preferable with respect to the heat resistant wet nonwoven fabric of this invention, 20-60 mass% is more preferable, 25-55 mass% is more preferable, and 30-50 mass% is still more preferable. In the said range, the intensity | strength of a heat resistant wet nonwoven fabric can be raised with an unstretched PPS fiber. When the content of unstretched PPS fibers is less than 20% by mass, the strength of the heat-resistant wet nonwoven fabric may be insufficient. Moreover, when it exceeds 60 mass%, there exists a possibility that heat resistance may be insufficient.

  1-40 mass% is preferable with respect to the heat resistant wet nonwoven fabric of this invention, 1-40 mass% is preferable, 2-35 mass% is more preferable, and 3-30 mass% is still more preferable. Within the above range, when a heat-resistant wet nonwoven fabric is produced by the wet papermaking method with the core-sheath type polyester composite fiber, the wet paper strength becomes strong, and fiber peeling or paper breakage occurs in the wet press part of the paper machine. It becomes difficult. Moreover, the strength after drying can be increased. When the content of the core-sheath type polyester composite fiber is less than 1% by mass, there is a risk of insufficient wet paper strength, peeling of the fiber at the wet press portion, or paper breakage. Moreover, when it exceeds 40 mass%, there exists a possibility that sticking to a heat roll may generate | occur | produce in the case of a heat | fever calendar process, and there exists a possibility that the heat resistance of a heat resistant wet nonwoven fabric may fall.

  In the present invention, a heat-resistant wet nonwoven fabric is produced by a wet papermaking method. First, a stretched PPS fiber, an unstretched PPS fiber, and a core-sheath type polyester composite fiber are uniformly dispersed in water, and then a slurry is prepared through a process such as screen (removal of foreign matter, lump etc.). The final fiber concentration of the slurry is preferably 0.01 to 0.50 mass%. The slurry is made up with a paper machine to obtain a wet paper. In the process, chemicals such as a dispersant, an antifoaming agent, a hydrophilic agent, an antistatic agent, a polymer viscosity agent, a release agent, an antibacterial agent, and a bactericide may be added.

  As the paper machine, for example, a paper machine using a paper net such as a long net, a circular net, or an inclined wire alone, or a combination paper machine in which two or more paper nets of the same type or different types are installed online is used. be able to. In addition, when the nonwoven fabric has a multi-layer structure of two or more layers, a paper making method in which wet papers made by each paper machine are laminated, or after forming one layer, fibers are dispersed on the layer. The nonwoven fabric can be produced by a casting method in which the slurry is cast to form a laminate. When casting the slurry in which the fibers are dispersed, the previously formed layer may be in a wet paper state or in a dry state. In addition, two or more dry layers can be thermally fused to form a multilayer nonwoven fabric.

  In the wet papermaking method, wet paper produced by a papermaking net and squeezed by a wet press section is dried by a dryer such as a Yankee dryer, air dryer, cylinder dryer, suction drum dryer, infrared dryer, etc. A wet nonwoven fabric is obtained. When the wet paper is dried, it is brought into close contact with a hot roll such as a Yankee dryer and dried by heat and pressure to improve the smoothness of the contacted surface. Hot-pressure drying means that wet paper is pressed against a hot roll with a touch roll or the like and dried. The surface temperature of the hot roll is preferably 100 to 180 ° C, more preferably 100 to 160 ° C, and still more preferably 110 to 160 ° C. The pressure is preferably 50 to 1000 N / cm, more preferably 100 to 800 N / cm.

  The heat resistant wet nonwoven fabric of the present invention is preferably subjected to thermal calendering. By softening the unstretched PPS fiber by carrying out thermal calendering, the intersection with the stretched PPS fiber and the core-sheath type polyester composite fiber can be brought into close contact, and the strength of the heat-resistant wet nonwoven fabric can be further increased. Moreover, the dimensional stability of the heat-resistant wet nonwoven fabric when exposed to high temperature can be improved. Examples of the calender unit used for the heat calender treatment of the heat-resistant wet nonwoven fabric include a calender unit of a combination of rolls such as a metal roll-metal roll, a metal roll-elastic roll, a metal roll-cotton roll, and a metal roll-silicon roll. It is done. These calendar units can be used alone or in combination of two or more.

  The surface temperature of the metal roll during the heat calendar treatment is preferably 100 to 260 ° C, more preferably 130 to 255 ° C, and further preferably 150 to 250 ° C. If the temperature of the metal roll is lower than 100 ° C., melting of the unstretched PPS fiber does not proceed and the fiber-fiber binding may not proceed. Moreover, when the temperature of a metal roll is higher than 260 degreeC, the fiber which comprises a heat resistant wet nonwoven fabric may stick to a metal roll, and the uniformity of the nonwoven fabric surface may be impaired.

  The nip pressure of the nip during the heat calendar process is preferably 190 to 1800 N / cm, and more preferably 390 to 1500 N / cm. The processing speed is preferably 5 to 150 m / min, and more preferably 10 to 80 m / min.

  In the present invention, when the heat-resistant wet nonwoven fabric has a multilayer structure, it may have a multilayer structure in which the fiber composition of each layer is the same, or may have a multilayer structure in which the fiber composition of each layer is different. In the case of a multi-layer structure, the fiber weight of the slurry can be lowered by lowering the basis weight of each layer, so that the formation of the heat resistant wet nonwoven fabric is improved, and as a result, the uniformity of the formation of the heat resistant wet nonwoven fabric is improved. Will improve. Moreover, even when the formation of each layer is non-uniform | heterogenous, it can compensate by laminating | stacking. Furthermore, the papermaking speed can be increased, and the operability can be improved.

Although the basic weight of the heat resistant wet nonwoven fabric manufactured with the manufacturing method of this invention is not specifically limited, Preferably it is 10-200 g / m < ² >, More preferably, it is 15-150 g / m < ² >. If the basis weight is less than 10 g / m ² , the uniformity and strength of the heat-resistant nonwoven fabric may be insufficient. If the basis weight exceeds 200 g / m ² , it may be difficult to uniformly apply heat to the heat-resistant wet nonwoven fabric during the heat calendar process.

  EXAMPLES Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited to the examples. In the examples, all parts and percentages are by mass unless otherwise specified.

(fiber)
Stretched PPS fiber: Fineness 1.7 decitex, fiber length 5 mm
Unstretched PPS fiber: Fineness 2.2 decitex, fiber length 5 mm
Core-sheath type polyester composite fiber (core-sheath type PET fiber): Fineness 1.1 dtex, fiber length 5 mm

<Examples 1-10, Comparative Examples 1-3>
In the fiber composition shown in Table 1, the fiber is dispersed in water at a dispersion concentration of 0.2% by mass for 10 minutes, a wet paper is formed using a paper machine, and then hot pressing with a Yankee dryer having a surface temperature of 150 ° C. It dried and obtained the heat resistant wet nonwoven fabric of basic weight 60g / m < ² >. In Examples 1 to 9 and Comparative Examples 1 to 3, a circular net paper machine was used. In Example 10, a heat-resistant wet nonwoven fabric was produced by a paper making method using a combination paper machine having a circular net (basis weight 30 g / m ² ) and an inclined net (basis weight 30 g / m ² ).

(Thermal calendar processing)
The heat-resistant wet nonwoven fabric was subjected to a heat calendar treatment at a metal roll temperature of 230 ° C. and a processing speed of 10 m / min by a metal roll-metal roll calendar unit.

  The following evaluation was performed on the workability during production of the examples and comparative examples, and the results are shown in Table 2.

(Paper making)
The paper making properties when producing a heat-resistant wet nonwoven fabric were evaluated by the following indices.

“5”: The running properties of the wet paper and the heat-resistant wet nonwoven fabric in each part of the paper machine were stable, and no paper break occurred. Speed increase is also possible.
“4”: The running properties of the wet paper and the heat-resistant wet nonwoven fabric in each part of the paper machine are stable. Paper breakage does not occur, but slight fiber peeling is observed.
“3”: The running properties of the wet paper and the heat-resistant wet nonwoven fabric in each part of the paper machine are stable. Paper breakage does not occur, but fiber peeling is more than “4”.
“2”: Although the strength of the wet paper in the press part is weak, it can be manufactured at a speed lower than “3”. Occasionally, a paper break may occur at the dryer exit.
“1”: The strength of the wet paper in the press part is weak, and the paper breaks frequently.

(Calendar workability)
The processability when the heat-resistant wet nonwoven fabric was subjected to thermal calendering was evaluated using the following indices.

“5”: When heat calendering is performed, no paper breakage occurs and processing can be performed without any problem, and the uniformity is excellent.
“4”: When heat calendering is performed, paper breakage does not occur, but a heat-resistant wet nonwoven fabric sticks to the heat roll, making it feel like it is.
“3”: When heat calendering is performed, paper breakage does not occur, but a heat-resistant wet nonwoven fabric is adhered to the heat roll, and partial peeling is observed.
“2”: A slight paper breakage occurs when the thermal calendar process is performed.
“1”: When the thermal calendar process is performed, paper breakage frequently occurs.

(Heat resistance test of heat resistant wet nonwoven fabric)
The tensile strength maintenance rate before and after heating the heat-resistant wet nonwoven fabric in a dryer at 200 ° C. for 60 hours was evaluated by the following index.
(Average value of tensile strength in MD direction and CD direction after heating / Average value of tensile strength in MD direction and CD direction before heating) × 100

“5”: 95% or more “4”: 90% or more, less than 95% “3”: 80% or more, less than 90% “2”: 70% or more, less than 80% “1”: less than 70%

  By comparing Examples 1 to 10 and Comparative Examples 1 to 3, the heat-resistant wet nonwoven fabric of Examples 1 to 10 containing stretched PPS fibers, unstretched PPS fibers, and core-sheath polyester composite fibers is stretched. When compared with the heat-resistant wet nonwoven fabrics of Comparative Examples 1 to 3 containing PPS fibers and unstretched PPS fibers, it can be seen that the papermaking properties are increased.

  By comparing Examples 1 to 6, which are heat-resistant wet nonwoven fabrics containing stretched PPS fibers, unstretched PPS fibers, and core-sheath polyester composite fibers, the content ratio of the core-sheath polyester composite fibers is 30% by mass. The heat-resistant wet nonwoven fabric of Example 4 is a calenderability and heat resistance test compared to the heat-resistant wet nonwoven fabric of Example 5 in which the content ratio of the core-sheath polyester composite fiber exceeds 30% by mass. It turns out that a result is favorable. Further, the heat-resistant wet nonwoven fabric of Example 2 in which the content ratio of the core-sheath polyester composite fiber is 3% by mass is the heat-resistant wet nonwoven fabric of Example 1 in which the content ratio of the core-sheath polyester composite fiber is less than 3% by mass. It can be seen that the papermaking properties and calendering results are better than those of the nonwoven fabric.

  From the comparison between Example 8 and Example 10, it can be seen that, even if the heat-resistant wet nonwoven fabric has a single layer or a multilayer structure, papermaking properties, calendar workability, and heat resistance test results are all good.

  The heat-resistant wet nonwoven fabric of the present invention includes a filter used for high-temperature gas dust collection, a canvas for a dryer used in a drying process for industrial products, a roll wiping material for an office copying machine, an insulating material for electrical equipment, a cushioning material (cushion material) ), Can be used as a heat insulation cloth.

Claims (2)

  A heat resistant wet nonwoven fabric containing polyphenylene sulfide fibers, comprising a stretched polyphenylene sulfide fiber, an unstretched polyphenylene sulfide fiber, and a core-sheath polyester composite fiber.   The heat-resistant wet nonwoven fabric according to claim 1, wherein a content ratio of the core-sheath polyester composite fiber is 3% by mass or more and 30% by mass or less.