JP3130235B2 - Nonwoven fabric, laminate thereof and method for producing nonwoven fabric - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonwoven fabric, a laminate thereof and a method for producing the nonwoven fabric, and can be used for bedding, flooring, and the like.

[0002]

BACKGROUND OF THE INVENTION Under high temperature and high humidity conditions such as the rainy season and summer season in Japan, indoor germs and ticks are easily generated. Not only during such a period, but also in recent years, with the completion of air-conditioning equipment, even during the winter season, the occurrence of various bacteria, mites, and the like has been observed.

[0003] The occurrence of such germs, ticks and the like is particularly problematic in bedding such as futons and beds and flooring materials such as underfloor materials. For example, a claw mite lurking in bedding causes biting with itching, especially in soft skin, while sleeping, and living mites, dead bodies, dung, etc. cause allergic asthma and the like. In addition, moisture caused by perspiration during bedtime increases the humidity in the bedding and promotes the growth of various bacteria, which is one of the causes of the bad smell of the bedding.

[0004] Bedding uses cloths of various patterns and thicknesses as surface materials, but it is economically difficult for a bedding maker to apply antibacterial and anti-mite treatment to all such surface materials. is there. In addition, in the case of antibacterial and mite-prevention processing by the usual application of a drug, there is a problem in persistence of the effect that the drug is dropped due to rubbing or the like during washing or use.
On the other hand, if a nonwoven fabric is used as a material for a futon and a drug is kneaded into the nonwoven fabric, good antibacterial properties and anti-mite properties can be expected.

[0005] However, in order to obtain a nonwoven fabric having various functions such as antibacterial and mite-proof properties at the same time, there is no limitation. In the case of extrusion molding as (1), even if the particle size of the drug is 1 to several μm, the drugs may aggregate during extrusion molding to form apparently aggregates of several tens of μm. If such agglomeration of drugs occurs during extrusion molding, fiber breaks called thread breaks occur in the process of obtaining continuous filaments having a small diameter, which causes manufacturing troubles and product defects.

[0006] On the other hand, the underfloor material is also provided with mite-proofing, insect-proofing, antibacterial properties, etc., and is made by mixing a thermoplastic resin foam into which a drug is kneaded or a fiber into which a drug is kneaded. A needle-punched nonwoven fabric made by impregnating a drug into a sheet-like material and the like are known.

However, the underfloor material generally requires a buffering property or the like, so that a high-weight product is mainly used, and an impregnated product uses a large amount of chemicals, so that it is costly, and the above-mentioned cohesion of the chemicals is caused. Lack of sex. In addition, the kneaded product is expensive in the case of foam because the material is expensive and it is necessary to knead expensive chemicals throughout the material.
In the case of a needle-punch type nonwoven fabric, the yarn breakage as described above is likely to occur in the step of obtaining the fiber into which the drug is kneaded,
Production is difficult and costly.

Accordingly, the present invention provides a laminate of a nonwoven fabric having both good antibacterial properties and mite resistance and having excellent durability, and a nonwoven fabric having good antibacterial properties and mite resistance and which can be produced at low cost. An object of the present invention is to provide a manufacturing method capable of stably manufacturing a body and a nonwoven fabric.

[0009]

The nonwoven fabric according to the first invention of the present invention contains 0.3 to 0.7% by weight of a silver-based antibacterial agent and 0.2 to 0.5% by weight of a synthetic pyrethroid-based miticide, and has a fiber diameter of But
It is characterized by being composed of a polyolefin of 10 to 50 μm.

The polyolefin includes polypropylene, polyethylene and the like. When the content of the silver-based antibacterial agent is less than 0.3% by weight, the antibacterial effect is reduced. If more than 0.7 wt% is contained, at the same time 0.2-
Yarn breakage occurs due to the effect of the synthetic pyrethroid-based acaricide containing 0.5 wt%, resulting in poor productivity. On the other hand, when the content of the synthetic pyrethroid-based tick-controlling agent is less than 0.2 wt%, the tick-controlling effect is reduced. If the content is more than 0.5% by weight, the silver antibacterial agent simultaneously containing 0.3 to 0.7% by weight will cause the thread breakage and lower the productivity.

When the silver-based antibacterial agent or the synthetic pyrethroid-based acaricide is contained alone, it may be contained in an amount exceeding the above upper limit. However, when a silver-based antibacterial agent and a synthetic pyrethroid-based acaricide are used together as in the present invention, in order to obtain good antibacterial properties and acaricide simultaneously, one content is restricted by the other content. In this case, the above-mentioned content makes it possible to sufficiently exert the effect of each drug.

As antibacterial agents, quaternary ammonium compounds and thiazoline compounds other than the silver antibacterial agents are known, but silver antibacterial agents are preferred in view of heat resistance. As anti-mite agents, carbamate compounds other than the synthetic pyrethroid compounds, aromatic carboxylate compounds, organic phosphorus compounds, natural pyrethroid compounds, etc. are known, but have heat resistance and antibacterial agents Use of a synthetic pyrethroid compound is preferred to enable stable production in the presence of the compound.

The synthetic pyrethroid-based acaricide is a compound similar to pyrethrin, an active ingredient in pyrethrum, (a chrysanthemic ester called pyrethroid), which has been synthesized. On the other hand, natural pyrethrin (pyrethrum extract) is extracted from dried pyrethrum flowers with an organic solvent and concentrated.

A nonwoven fabric according to a second aspect of the present invention is the nonwoven fabric according to the first aspect, wherein the silver-based antibacterial agent is a silver zirconium phosphate compound. The silver zirconium phosphate compound has an average particle diameter of 1 μm or less and has a small particle diameter, and is therefore preferable in preventing yarn breakage.

The nonwoven fabric of the present invention is a spunbonded nonwoven fabric made of continuous filaments (filaments). When the fiber diameter of the nonwoven fabric is smaller than 10 μm, thread breakage occurs and stable production cannot be performed. On the other hand, if it is larger than 50 μm, the fiber diameter is large and the feel becomes hard, which is not preferable as the quality of the nonwoven fabric.

The laminate of the nonwoven fabric according to the third invention of the present invention is characterized in that the nonwoven fabric of the first invention or the second invention is laminated on at least one surface of a sheet-like structure made of a thermoplastic resin. And The basis weight of the nonwoven fabric is not particularly limited. However, if the basis weight is too large, it is disadvantageous in terms of cost. If the basis weight is too thin, the nonwoven fabric is damaged due to abrasion during use. Considering both of these, the basis weight of the nonwoven fabric
Is preferably 15 to 100 / m ^2, even 15 to 80 g / m ²
It is preferred that

The basis weight of the sheet-like structure is not particularly limited, but it is preferably 100 g / m ² or more in order to provide a cushioning property in consideration of uses such as underfloor materials. Any thermoplastic resin can be used as long as it can be foamed or spun, and can be appropriately selected so as to satisfy the intended use and required characteristics. For example, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyethylene terephthalate (PET), polybutylene terephthalate (PB)
T), vinyl chloride resin and the like.
P, PE, PS, PET. The expansion ratio, the fiber diameter and the fiber length of the fibrous formed body are appropriately set as required.

As a method of laminating the sheet-like structure and the nonwoven fabric, a general method can be appropriately selected. For example, lamination using an adhesive, heat seal lamination, extrusion lamination, emboss lamination, lamination using rivet screws or pins, and the like can be mentioned.

The laminate of the nonwoven fabric according to the fourth invention of the present invention is the laminate of the third invention, wherein the sheet-like structure is selected from a foam made of a thermoplastic resin and a needle-punched nonwoven fabric made of a thermoplastic resin. And at least one of them.

By forming the sheet-like structure including a foam made of a thermoplastic resin or a needle-punched non-woven fabric, a laminate having an antibacterial property and an anti-mite property and a relatively high weight can be obtained at a low cost. It can be effectively used for underfloor materials.

In the method for producing a nonwoven fabric according to the fifth invention of the present invention, the method comprises kneading a polyolefin raw material containing 0.3 to 0.7% by weight of a silver-based antibacterial agent and 0.2 to 0.5% by weight of a synthetic pyrethroid-based acaricide. Fiber diameter 10-50μ from polyolefin raw material
m, and a nonwoven fabric is obtained from the filament.

The method for producing a nonwoven fabric generally includes a melting / kneading step of melting and kneading the raw materials, a spinning step of extruding the molten resin from a spinning nozzle to form continuous filaments (long fibers), and a sheet in which filaments are randomly accumulated. The method includes a thermocompression bonding step of passing the (web) between embossing rolls and thermocompression bonding to produce a nonwoven fabric, a slitting process of dividing the nonwoven fabric into a required size, and a winding process of winding the slit nonwoven fabric.

The use of the nonwoven fabric according to the present invention includes disposable sheets, pillow covers and the like. In beddings such as futons and beds, mites and various germs are often present inside. Therefore, it is effective to use the nonwoven fabric of the present invention so as to cover such bedding. For example, in hospitals,
Sheets, pillowcases, etc. are cleaned daily and used repeatedly, but since this nonwoven fabric is inexpensive, disposable is more economical in consideration of cleaning, and has antibacterial properties and anti-mite properties Because it is very hygienic.

[0024]

【Example】

[Example 1] Polyolefin, polypropylene (M
I = 50), using a silver zirconium phosphate compound as a silver-based antibacterial agent and a synthetic pyrethroid-based compound as an acaricide, with 0.3% by weight of silver-based antibacterial and 0.2wt. %. Here, a master batch was prepared in which each agent was added to polypropylene (MI = 50) so that the content was 10 wt%,
These were used to adjust the blending amount.

The compounded raw material is put into an extruder, melted and kneaded at a resin temperature of 220 ° C., and the melted resin is extruded from a die (200 holes), stretched and thinned with high-speed air to form a continuous filament ( Long fiber). next,
After the filaments are randomly accumulated to form a sheet (web), the sheet is subsequently passed between a roll having an embossed pattern and a roll having a smooth surface, and hot-embossed at 140 ° C. to form a nonwoven fabric. Produced.

Next, after slitting the nonwoven fabric to a required size, the slit nonwoven fabric was wound up to produce a continuous long-fiber nonwoven fabric of this example. This nonwoven fabric had a fiber diameter of 22.4 μm and an average basis weight of 50 g / m ² .

For this example, the production stability during the production of the nonwoven fabric, the antibacterial properties of the nonwoven fabric and the anti-mite properties were evaluated. The evaluation of the production stability was performed by measuring the following production stability index (γ). That is, continuous production was performed for 6 hours, and the number of times of yarn breakage was measured. The number of repetitions was set to 3, and the average was taken. When this index is 3 or less, there is almost no occurrence of yarn breakage, and stable production is possible.

[0028]

(Equation 1)

The antibacterial properties of the nonwoven fabric were evaluated by measuring the sterilization rate based on the shake flask method (Fiber Sanitary Processing Council). That is, 0.5 g of the nonwoven fabric was finely cut, put into 15 ml of a phosphate buffer solution containing 0.1% of a surfactant (Tween 80, trade name), further added with Staphylococcus aureus and shaked, and the viable cell count after 1 hour was counted. Measure. The sterilization rate is determined by the following equation.

[0030]

(Equation 2)

The evaluation of the anti-mite property of the nonwoven fabric was carried out by measuring the rate of mites repelling. That is, a plastic petri dish (4 cm in diameter, 0.6 cm in height) is placed on an adhesive sheet, and six identical petri dishes are placed around the sheet so that the edge of the petri dish is in contact with the center petri dish. Approximately 3000 surviving mites were put into the petri dish at the center of the petri dish, and a mite culture medium was prepared.
A nonwoven fabric containing a drug and a nonwoven fabric containing no drug cut into cm are alternately placed, and 0.05 g of a powder feed free of mites is placed on each sample. Put this in a plastic container for food preservation (27 x 13 x 9 cm) together with the adhesive sheet,
Cover with saturated saline and cover the container with humidity of about 75
Keep at%. Next, the container is placed in a thermostat kept at 25 ± 1 ° C. and bred for 24 hours a day. The next day, after collecting the mites,
Apply the following formula to determine the repellent rate. The test was repeated three times in consideration of test variations.

[0032]

(Equation 3)

[Examples 2 to 4] The nonwoven fabrics of the respective examples were obtained in the same manner as in Example 1 except that the amount of the antibacterial agent and the amount of the anti-mite agent added in Example 1 were changed as shown in Table 1. In the same manner as in Example 1, the production stability of the nonwoven fabric of each of the examples and the antibacterial and mite-proof properties of the nonwoven fabric were evaluated. Table 1 shows the results.

Comparative Examples 1 to 4 Non-woven fabrics of Comparative Examples were obtained in the same manner as in Example 1 except that the amount of the antibacterial agent and the amount of the acaricide added in Example 1 were changed as shown in Table 2.

[Comparative Examples 5 and 6] The same as in Example 1 except that the anti-mite agent in Example 1 was changed to an aromatic carboxylic acid ester compound, and the amounts of the antibacterial agent and the anti-mite agent were as shown in Table 2. Thus, nonwoven fabrics of the respective comparative examples were obtained. Comparative Example 1 above
In the same manner as in Example 1, the nonwoven fabrics Nos. 6 to 6 were evaluated for the production stability during the production of the nonwoven fabric, the antibacterial property of the nonwoven fabric, and the anti-mite property. Table 2 shows the results.

[0036]

[Table 1]

[0037]

[Table 2]

As shown in Table 1, the nonwoven fabric according to this embodiment contains 0.3 to 0.7% by weight of a silver-based antibacterial agent and a synthetic pyrethroid-based tick-proofing agent.
Since it contains 0.2 to 0.5 wt% and is made of polyolefin having a fiber diameter of 22.4 μm, it can be seen that both the antibacterial property and the anti-mite property are good.

Further, according to the method for producing a nonwoven fabric according to the present embodiment, after kneading a polyolefin raw material containing 0.3 to 0.7% by weight of a silver-based antibacterial agent and 0.2 to 0.5% by weight of a synthetic pyrethroid-based acaricide, Fiber diameter 22.4 from this polyolefin raw material
Since a non-woven fabric is obtained from the filament by producing a filament of μm, there is no occurrence of thread breakage,
Good production stability.

On the other hand, from Table 2, according to Comparative Example 1, the content of the anti-mite agent is within the range of the present invention, but the antimicrobial content is less than the range of the present invention, so that the antibacterial property is poor. It is. According to Comparative Example 2, although the content of the anti-mite agent is within the range of the present invention, the production stability is poor because the content of the antibacterial agent is larger than the range of the present invention.

According to Comparative Example 3, the content of the antibacterial agent is within the range of the present invention, but the content of the anti-mite agent is less than the range of the present invention, so that the anti-mite property is poor. According to Comparative Example 4, the content of the antibacterial agent is within the range of the present invention, but the content of the anti-mite agent is larger than the range of the present invention, so that the production stability is poor.

According to Comparative Example 5, since an aromatic carboxylic acid ester compound was used as an acaricide, even if the content of the acaricide was set to 0.8 w%, which is larger than the range of the present invention, the mite-proof property was poor. It is. According to Comparative Example 6, when the content of the tick-controlling agent is further increased as compared with Comparative Example 5, even if the tick-controlling property is improved, the production stability becomes poor.

Example 5 The antibacterial agent and the anti-mite agent of Example 1 were blended so as to be 0.7% by weight and 0.5% by weight, respectively, and a polypropylene filament having a basis weight of 20 g / m ^{2 was} prepared in the same manner as in Example 1. A non-woven fabric was obtained. The combined amount of the antimicrobial agent and the anti-mite agent was 0.238 g / m ² .

With respect to the obtained nonwoven fabric, the transpiration rate of the medicine was measured. That is, 1 m ² of the sample was suspended in a constant temperature room at 25 ° C. and allowed to stand for one year, and the weight before and after the standing was measured to determine the evaporation rate of the drug. Table 3 shows the results.

[Comparative Example 7] A weight per unit area was obtained in the same manner as in Example 1 except that the antibacterial agent and the anti-mite agent in Example 1 were not blended.
A PP long-fiber nonwoven fabric of g / cm ² was produced, and impregnated with the same antibacterial agent and mite-proofing agent as in Example 5 so as to be 0.7 wt% and 0.5 wt%, respectively, to obtain a nonwoven fabric of this comparative example. The applied amount of the combination of the antibacterial agent and the anti-mite agent was 0.235 g / m ² . About the obtained nonwoven fabric, the transpiration rate of the medicine was measured in the same manner as in Example 5. Table 3 shows the results.

[0046]

[Table 3]

From Table 3, it can be seen that the non-woven fabric of Example 5 has a chemical vaporization rate lower than that of the non-woven fabric of Comparative Example 7 impregnated with the chemical, because the chemical is added by kneading, and the durability is improved. It turns out that it is excellent.

[Embodiment 6] Similar to the embodiment 1, the basis weight 30
g / m ² polypropylene long-fiber nonwoven fabric was produced. In addition,
The combined amount of the antimicrobial agent and the anti-mite agent is 0.15 g /
It was m ^2. In the needle punch type nonwoven fabric production line,
Polyester fiber is laid on this polypropylene non-woven fabric so that the weight per unit is 70 g / m ^2, and the polyester fiber is punched with a needle as it is to form a polyester needle punched non-woven fabric with a weight per unit of 100 g / m ² which is a sheet-like structure. A laminate with a polypropylene long fiber nonwoven fabric was obtained.

The obtained laminate was tested for antibacterial and mite-proof properties in the same manner as in Example 1. Table 4 shows the results. In addition, both the sterilization rate and the mite repellency of the laminate of the polyester needle punched nonwoven fabric and the polypropylene long-fiber nonwoven fabric manufactured without adding the chemical were 0%.

Example 7 A nonwoven polypropylene fabric having a basis weight of 30 g / m ² obtained in the same manner as in Example 6 was superposed on one side of crosslinked foamed polyethylene having a basis weight of 200 g / m ² , The sheet was passed through a smooth roll and hot-embossed at 140 ° C. to obtain a laminate in which a nonwoven fabric was laminated on one side of the foam as a sheet-like structure. About the obtained laminated body, the antibacterial property and the mite-proof property were evaluated like Example 1. Table 4 shows the results.

Comparative Examples 8 to 11
The crosslinked foamed polyethylene of each comparative example having a basis weight of 230 g / m ² was obtained. The same antibacterial agent and anti-mite agent as in Example 1 were used. The sterilization rate and the mite repellent rate of the crosslinked foamed polyethylene of each comparative example were examined in the same manner as in Example 1. Table 4 shows the results.

[0052]

[Table 4]

According to Table 4, the laminates according to Examples 6 and 7 are:
0.3% by weight of silver-based antibacterial agent and synthetic pyrethroid-based miticide
Since the nonwoven fabric made of polyolefin having a fiber diameter of 22.4 μm and containing 0.2 wt% is laminated on one side, it can be seen that both antibacterial properties and antimite properties are good.
This makes it possible to avoid invasion of various bacteria and mites into the sheet structure only by laminating the nonwoven fabric of Example 1 on the surface of the sheet structure, and to provide excellent antibacterial properties and prevention of the entire laminate. It can be seen that tickness can be imparted. Also,
Since it is only necessary to mix the drug in the polypropylene non-woven fabric, the amount of the drug used is small, and it is economical.

According to Comparative Examples 8 to 10, both the antibacterial property and the anti-mite property are poor, though a larger amount of the drug is kneaded into the whole crosslinked foamed polyethylene than in Example 7. Although the mite repellent rate and the sterilization rate of the laminate of Example 6 are slightly lower than those of Comparative Examples 2, 4, and 6, they have a large number of thread breaks and do not fit the production base as a business. Comparative Example 1
The laminate of No. 1 had a tick repellency equivalent to that of Example 7, but the compounded amount of the compound used was about 17 times that of Example 7,
Obviously costly.

[0055]

According to the nonwoven fabric of the present invention, 0.3 to 0.7% by weight of the silver-based antibacterial agent and 0.2% of the synthetic pyrethroid-based tick preventive agent are used.
Since it is made of a polyolefin having a fiber diameter of 10 to 50 μm containing 0.5 to 0.5 wt%, good antibacterial properties and anti-mite properties can be obtained at the same time. ADVANTAGE OF THE INVENTION According to the laminated body of the nonwoven fabric which concerns on this invention, favorable antibacterial property and mite-proof property with respect to the whole laminated body can be obtained reliably at low cost.

According to the method for producing a nonwoven fabric according to the present invention, a polyolefin material containing 0.3 to 0.7% by weight of a silver-based antibacterial agent and 0.2 to 0.5% by weight of a synthetic pyrethroid-based mite-proofing agent is kneaded. Fiber diameter 10-50 from polyolefin raw material
Since a non-woven fabric is manufactured from a filament having a thickness of μm and a non-woven fabric is manufactured from the filament, a non-woven fabric can be stably manufactured without occurrence of thread breakage.

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-7-54208 (JP, A) JP-A-6-228823 (JP, A) JP-A-6-2220 (JP, A) 53595 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) D04H 1/00-18/00 B32B 1/00-35/00 D01F 6/04-6/06

Claims (5)

(57) [Claims] 1. A silver-based antibacterial agent containing 0.3 to 0.7% by weight, a synthetic pyrethroid-based miticide 0.2 to 0.5% by weight, and a fiber diameter of 10 to 10%.
A non-woven fabric comprising 50 μm polyolefin. 2. The nonwoven fabric according to claim 1, wherein said silver-based antibacterial agent is a silver zirconium phosphate compound. 3. A laminate of a nonwoven fabric, wherein the nonwoven fabric according to claim 1 or 2 is laminated on at least one surface of a sheet-like structure made of a thermoplastic resin. 4. The nonwoven fabric laminate according to claim 3, wherein the sheet-like structure includes at least one selected from a foam made of a thermoplastic resin and a needle-punched nonwoven fabric made of a thermoplastic resin. A laminate of a nonwoven fabric, characterized in that: 5. After kneading a polyolefin material containing 0.3 to 0.7% by weight of a silver-based antibacterial agent and 0.2 to 0.5% by weight of a synthetic pyrethroid-based miticide, a filament having a fiber diameter of 10 to 50 μm is produced from the polyolefin material. And producing a non-woven fabric from the filament.