JP4000019B2 - Functional composite fiber nonwoven fabric and composite composition using the same - Google Patents

Description

【００５１】
（実施例１〜７、比較例１〜２） 本発明の伸縮性複合繊維メルトブロー不織布は、表１の樹脂を用い、前記の工程で表２の条件で不織布化した。なお紡糸温度とはノズル温度のことであり、同温度の高圧熱風を用いて噴出させ、これを噴出熱風量の５倍以上の吸引量で吸引して、コンベアー上に集積し、実施例と比較例の複合繊維不織布を得た。実施例１および２で得られた複合繊維不織布の引張試験結果（Ｓ−Ｓ曲線）を図４〜７に示す。
（尚、このＳ−Ｓ曲線はオリエンテック社製のテンシロンＵＣＴ−１Ｔを使用し、ロードセル定格：１０ｋｇｆ、試験速度：３００ｍｍ／ｍｉｎ、チャック間距離：１０ｃｍの条件による。）
【００５２】
また、実施例１の伸張繰り返し試験の結果を表２に例示する。表中の繊度は、数平均の繊維径μｍで、融着繊維は除外しており、各繊維層は少なくとも２回の集積回数のもので、その総目付けｇ／ｍ2で表示し、厚みは通常の不織布厚み計で常法通り測定し、単位は百μｍである。但し、ＰＢはハードポリマーのためＤ硬度で表示した。Ｄ硬度はＡ硬度同様にＡＳＴＭ−Ｄ２２４０法による。
【００５３】
【表２】

【００５４】
比較例１は、実施例１のＥＯエラストマーの代わりに、ショアーＡ硬度が３９のＤＹ樹脂を用いたもので、繊維間の融着が酷く不織布とは言えず、フィルム状のものになった。また、比較例２は、後記する実施例８であるが、伸縮性はなかった。
【００５５】
実施例７は実施例１の繊維を、コンベアー上に１５ｇ目付けで約７ｄＴｅｘのＰＰスパンボンド不織布を配し、その上からメルトブローして積層した不織布で、積層した不織布としては、スパンボンド不織布の抗張力でスパンボンド不織布の強伸度を示し、これらは簡単に剥離できた。
【００５６】
（実施例８〜１０、比較例３）本発明のノンスリップ性メルトブロー不織布は、表１の樹脂と、軟質のメチルアクリレートが２１質量％で融点が９０℃のエチレンーアクリル酸エステル共重合体ＥＭを用い、実施例１と同様にして、前記の工程で表２の条件で不織布化し実施例と比較例の複合繊維不織布を得た。いずれもノンスリップ性（滑り止め性）の高い不織布で、当然のことながら伸縮性はなかった。
【００５７】
（実施例１１）実施例８の不織布を、ポリエチレンテレフタレートの３ｄＴｅｘ繊維のアクリル樹脂含浸した、目付け６０ｇ／ｍ2のケミカルボンド不織布の上に直接メルトブローして接着した複合不織布を作成した。該不織布は実施例８の不織布を床面に接する様にして置いて、ケミカルボンド不織布を蹴る様にして歩いても、床面からずれたり滑ったりはしなかった。
【００５８】
【発明の効果】
本発明は、従来からステープル繊維で使用されてきた熱可塑性樹脂を用いた複合繊維をメルトブロー繊維化手法を用いて、直接不織布化した点にあり、ステープル繊維やマルチフィラメント繊維などの従来の繊維化手法では、極めて深刻な問題となっていた、融着し易い熱可塑性樹脂を積極的に利用できる点にあり、特に好ましいのは前記した融着し易い樹脂を繊維表面に用いた複合繊維であるが、この融着現象を積極的に利用して、繊維の噴出中に繊維の部分融着を起こさせ、凝集して絡み合い融着接着した、エラストマー成分が繊維表面の過半を占めさせたことを特徴とするメルトブロー複合繊維不織布である。
本発明は上記のような構成を採用することにより、伸縮性に富んだ、またはノンスリップ性に富んだ、メルトブロー機能性複合繊維不織布およびこれを複合化した複合組成物が得られ、多用途な商品展開が可能な不織布材となり得る。
【図面の簡単な説明】
【図１】 伸縮性能に優れた本発明の機能性複合繊維不織布の平面拡大写真である。
【図２】 滑り止め性能に優れた本発明の機能性複合繊維不織布の平面拡大写真である。
【図３】 Ａ：猫目型複合繊維の繊維断面図である。
Ｂ：鞘芯型複合繊維の繊維断面図である。
Ｃ：３層型複合繊維の繊維断面図である。
【図４】 実施例１の伸縮性不織布の縦方向Ｓ−Ｓ曲線である。
【図５】 実施例１の伸縮性不織布の横方向Ｓ−Ｓ曲線である。
【図６】 実施例２の伸縮性不織布の縦方向Ｓ−Ｓ曲線である。
【図７】 実施例２の伸縮性不織布の横方向Ｓ−Ｓ曲線である。
【符号の説明】
１ 芯成分
２ 鞘成分
３ 複合繊維が部分的に凝集し絡み合い溶融接着した塊部分[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a melt blown composite fiber nonwoven fabric and a composite composition using the same. Generally, by using a melt viscosity thermoplastic resin for producing staple composite fibers, fiber properties such as the waist of the fibers are the same as staple composite fibers, and finer composite fibers or thicker composite fibers are manufactured. Melt blow that can make composite fibers by using a fiber aggregate such as a fiber web that has been directly opened or a non-woven fabric integrated by fusion bonding without using a roller card or the like that restricts the use of composite fibers to make non-woven fabrics. The present invention relates to a composite fiber nonwoven fabric in which fiberization and non-woven fabric are simultaneously performed using the equipment of the method, and the conventional fiber technique such as roller card is impossible or extremely difficult, and a composite composition to which these are applied. .
[0002]
In particular, the present invention has a problem in that a staple fiber is conventionally produced by fusion bonding between the spun fibers at the time of spinning, a resin having a low melting point, a softness and a surface hardness, and a low stress. It is possible to make a composite fiber using a resin that could not withstand taking-up because it stretched easily, and to easily make a nonwoven fabric of a composite fiber using a resin that has poor spinnability and cannot be made alone. The present invention relates to these composite fiber nonwoven fabrics, composite nonwoven fabrics and composite compositions to which these are applied.
[0003]
These are highly stretchable and have hygienic materials such as emergency clothes that require stretch, and some have anti-slip effects, so they are used as non-slip materials for daily goods and furniture, and there is a demand for non-slip properties. The present invention relates to a non-slip functional material that achieves non-slip by directly bonding to a material.
[0004]
[Prior art]
Conventionally, a melt blown fiber has a single fiber made of one kind of thermoplastic resin, and a fiber having a fiber diameter of generally 5 μm or less is required. Therefore, its melt flowable melt flow rate (MFR: g / Generally, a resin having 10 minutes) is 300 or more.
[0005]
In recent years, a patent for a fiber assembly of a melt-blow technique using a plurality of thermoplastic resins has been published, and one of them is that two resins are discharged alternately from nozzles arranged in an orderly manner in the width direction. It is a non-woven fabric in which fibers are mixed, and the other is not described in detail, but there is a description of a composite fiber such as a sheath core type composite fiber or a dorsal belly type composite fiber. Is described in detail in Japanese Patent Publication No. 6-53987 and Japanese Patent No. 3134959, but a practical sheath-core type composite fiber or a composite fiber in which most of the fiber surface is covered with one component is made by a melt blow method. There was no disclosure of fiber assemblies such as nonwoven fabrics.
[0006]
[Problems to be solved by the invention]
The current melt-blown nonwoven fabric is composed of a single component, so most of the nonwoven fabric is not self-bonding, has a problem with lint-free properties, and is low in volume and thin like paper. It was only a non-woven fabric. As described above, the non-woven fabric of the present invention composed of fibers made by a melt-blow technique and its application products are composite fibers, and thus can be fused and fused, and at least during fiber accumulation or thermal processing. The thermoplastic resin component occupying the majority of the fiber surface of the composite fiber is bonded and integrated, and the lint-free property as well as the entire nonwoven fabric is adhered, so the strength of the nonwoven fabric is considerably improved.
[0007]
The commercially available melt blown nonwoven fabric was investigated, and it was found that each constituent fiber was accumulated in a fairly ordered manner along the jet blown air flow of the melt blow as in the case of Japanese Patent Application Laid-Open No. 2001-98453 electret nonwoven fabric by the present applicant. That is, as the fibers constituting the nonwoven fabric become thinner, it is obvious that the nonwoven fabric has a uniform arrangement direction of fibers, and it is difficult to expand and contract freely in the vertical and horizontal directions by this method. Randomness is required. The same applies to non-slip nonwoven fabrics.
[0008]
The present inventor has been developing a thermoplastic rubber, a thermoplastic soft resin, and a thermoplastic elastomer into a composite staple fiber, all of which require great efforts and devices in the fiber opening process for making a nonwoven fabric. Has led to an invention. Polyurethane resin found in JP-A-59-157362 is made into a nonwoven fabric by a melt-blow technique, and is optimal for making these flexible and soft resins into a non-woven fabric. However, the present inventor has no development means, An attempt was made to fabricate the softness and nonwoven fabric of the composite staple fiber and the soft resin. In either case, a roller card, which is a fiber opening means, is passed, so that a thermoplastic resin that is relatively solid is used for the core component, and the resin is used for the sheath component for exhibiting the function. Patent 2587706 uses a thermoplastic rubber, syndiotactic 1 · 2-polybutadiene, and non-slip fibers and non-woven fabrics are made of a soft resin or thermoplastic elastomer having a low melting point in Patents 2664466, 3159653 and 2571155. The elastomer fiber cannot be passed through the elastic fiber and non-woven fabric, so that very fine crimps (secondary crimps) are generated by thermal processing. Thus, it has been proposed with the crimped elastic fiber and the non-woven fabric of Patent No. 2759331 and Patent No. 2772532. Due to the composite fibers, these fibers are significantly more sticky and sticky, which are disadvantages of rubbers and elastomers in daily goods than the polyurethane fiber nonwoven fabrics disclosed in JP-A-59-157362. It was low.
[0009]
The present invention uses these sticky feelings and sticky feeling elastomers, etc., while maintaining the elasticity and non-slip characteristics of rubber elasticity, which are the characteristics of these rubbers and elastomers, are more preferable for daily goods. It proposes non-woven fabrics with reduced or eliminated feelings of stickiness, and has improved functionality and improved economics, such as productivity and ease of production by simplifying the process, compared to the staple composite fibers and non-woven fabrics mentioned above. It aims for further improvement.
[0010]
Further, as described above, unlike a film, a non-woven fabric is characterized by its thickness and air permeability, and the non-woven fabric is also expected to have a cushioning property due to its thickness. It is necessary to be a little bulky than the present situation.
[0011]
Furthermore, in a stretchable nonwoven fabric, it is possible to make a rubber elastic nonwoven fabric with a higher degree of elongation by dividing it into a stretched and contracted portion, so that the overall nonwoven fabric and partial strong adhesion can be achieved. is necessary. An object of the present invention is to solve the above-described problems and to provide functionality.
[0012]
[Means for Solving the Problems]
The inventor of the present invention basically uses the electret nonwoven fabric disclosed in Japanese Patent Application Laid-Open No. 2001-98453, in the same manner as a conventional melt-blown nonwoven fabric, that each single fiber is neatly ejected in a cage shape and fused and adhered when the fibers are accumulated. However, although it is of course ejected orderly, at least a few percent of adjacent fibers are partially brought into contact with each other during ejection, and the aggregated, entangled, fused and bonded mass that is partially and locally unevenly distributed is rather By actively generating, for stretch (rubber elastic) non-woven fabric applications, a partial strong adhesion part is generated, and for anti-slip (non-slip) non-woven fabric applications, an integrated plane on which composite fibers are accumulated is provided. By forming unevenness and further accumulating composite fibers from above, we create three-dimensional accumulation conditions in the thickness direction and actively carry out fiber accumulation to lower fiber density, and as a result, non-woven To achieve bulking of is to that achieved an improvement in breathability spread together interfiber gaps and fiber intersection gap. In addition, when the agglomerated, entangled, and fusion-bonded lumps that are locally distributed are made, randomization of the fiber orientation direction was also achieved.
[0013]
The present invention has a low melting point, tackiness, and softness of the surface hardness, which is a problem of fusion bonding between the spun fibers at the time of spinning, and has a sticky feeling and a sticky feeling when making staple fibers. It is a composite fiber using an elastomer that cannot withstand take-up because it stretches at a low stress, and is made of a fiber that has greatly improved its stickiness and stickiness. That is, the present invention is a functional composite fiber nonwoven fabric comprising a composite fiber composed of a thermoplastic elastomer having a Shore A hardness (A) of 50 or more according to ASTM-D2240 method, the majority of the fiber surface made by the melt blow method. Thus, the nonwoven fabric has excellent functionality such as stretchability or anti-slip performance.
[0014]
One of the functions of the present invention is a functional composite fiber meltblown nonwoven fabric rich in stretch, and a sheath core type comprising a substantially continuous thermoplastic elastomer having a fiber diameter (d: μm) of 100>d> 3. A composite fiber in which most of the fiber surface is covered with a single component, such as an eccentric sheath-core type, cat-eye type, or three-layer type composite fiber, and has a Shore A hardness (A) of 70 or more and a fluid The majority of the fiber surface is covered with a component whose starting temperature or melting point is lower than that of the core component, and each of the constituent components has a flow starting temperature or melting point (Tm: ° C) of 60 <Tm <210, its melting Fluidity melt flow rate (MFR: g / 10 min; measurement temperature is 230 ° C., weight is 2.169 Kg, according to JIS-K-6760) is 5 <MFR <200, Shore A hardness is 50 or more Plastic elastomer -It is a resin and is made by a melt blown technique in which fibers are blown off from the spinneret with hot air, and the composite fiber is formed into a flat fiber aggregate in which there are lumps in which the composite fibers are partially agglomerated and entangled and fused. It is a functional composite fiber nonwoven fabric having a stretchability that is at least fusion bonded and / or melt bonded and bonded and integrated with a component covering the majority of the surface, and covers the majority of the fiber surface of the thermoplastic elastomer. At least a majority of a polyolefin elastomer whose component is a copolymer of a plurality of types of monomers selected from ethylene and α-olefin, particularly preferably a low melting point soft ethylene copolymer containing at least 20% by mass of octene-1. What consists of the elastomer which contains is preferable.
[0015]
Another function is a functional composite fiber melt blown nonwoven fabric having a so-called non-slip performance that has an excellent anti-slip effect. The flow start temperature or melting point (Tm: ° C.) is 60 <Tm <210, and its melt flowable melt flow rate ( MFR: g / 10 min; measurement temperature is 230 ° C., weight is 2.169 Kg, according to JIS-K-6760), but 5 <MFR <200, Shore A hardness is 50 or more, thermoplastic elastomer resin with fiber surface The resin occupying the majority of the fiber has a melting point at least 20 ° C. higher than the elastomer or higher than the flow start temperature, and its melting point (TM: ° C.) is 90 <TM <270. Melt flow rate (MFR: g / 10 min; measurement temperature is 230 ° C. when TM ≦ 200 ° C., 290 ° C. when TM ≧ 200 ° C., weight is 169 Kg, conforming to JIS-K-6760) is a thermoplastic resin with 5 <MFR <200, such as a sheath core type, an eccentric sheath core type, or a cat-eye type composite fiber, and the fiber diameter (D: μm) 100>d> 3, a substantially continuous mass produced by a melt blow technique in which fibers are blown off with hot air from a spinneret, and the composite fibers are partially agglomerated and entangled and fused and bonded. Is a functional composite fiber nonwoven fabric having a high anti-slipping effect, at least fusion-bonded and / or melt-bonded with a component covering a majority of the fiber surface, and united and integrated.
[0016]
In addition, in order to generate an agglomerated, entangled, fused, and bonded lump that is partially and locally contacted between adjacent fibers during ejection, and is partially and locally unevenly distributed, the facility response is extremely high. There was an effect. The nozzle of this place proposed with the electret nonwoven fabric of the said Unexamined-Japanese-Patent No. 2001-98453 made the space | interval of a discharge hole 3 mm, and was impossible to make adjacent fibers contact intentionally. After that, in order to solve the problem and improve productivity and make the melt blown fiber thinner, the interval between the discharge holes was reduced, and a nozzle with a large number of discharge holes was devised, and the interval between the discharge holes is now less than 1 mm. Artificially, we succeeded in generating agglomerated, entangled and fused bonded masses. That is, when making a non-woven fabric with many lumps that have been flocculated and entangled and fused, it is better to increase the discharge rate and slightly reduce the flow rate of hot air. Time can be achieved by reducing the discharge amount and increasing the hot air flow velocity. This utilizes the ballast effect of the resin.
[0017]
In the present invention, it is convenient to use a high-viscosity resin rather than a high-flow (low-viscosity) thermoplastic resin, and it is convenient to set the MFR of the resin to be used to be less than 200 g / 10 minutes. If it is less than 5 g / 10 minutes, this is a good direction, but it is excluded because it is difficult to produce fibers with a fiber diameter of 5 μm or less according to the present invention. Of the thermoplastic resins used, the flow starting temperature or melting point (Tm: ° C.) of the resin covering the majority of the fiber surface is advantageously in the range of 60 <Tm <210. If the melting point was less than 60 ° C., it was excluded from the claims because it was difficult to control the adhesion due to the excessive adhesion. At 210 ° C. or higher, it was excluded from the scope of claims because it was difficult to fuse and bond, and for the purpose of fusion bonding, the flow start temperature or melting point of the resin (core component) occupying the center of the fiber was the resin on the fiber surface. It is preferably at least 20 ° C higher, and the fiber constituting the non-slip nonwoven fabric of the present invention preferably has a melting point of 90 to 270 ° C. Since the core component thermoplastic resin could not be obtained due to temperature restrictions of the melt blow equipment used, the claim for the melting point of the resin used was less than 270 ° C., and 270 ° C. or higher was excluded. Therefore, it is considered that there is no inconvenience even at 270 ° C. or higher. The relationship between the resin covering the majority of the fiber surface described above (melting point: Tms: ° C.) and the melting point of the core component resin (Tmc) is preferably Tms + 20 ≦ Tmc. When using a resin covering the majority of the surface, if both of these components or a combination thereof have fiber moldability, Tms> Tmc and there is no inconvenience. Since the requirement of Tms + 20 ≦ Tmc of the planned fiber is necessary, this condition is excluded from the claims. The Shore A hardness is an index of the hardness of the thermoplastic elastomer, and there is no problem at 30 or more when it is made into a fiber, but the fiber surface is formed in order to suppress the stickiness and stickiness of rubber and elastomer. The hardness is limited only to the resin. Generally, the Shore A hardness may be 50 or more. However, in the case of a rubber elastic nonwoven fabric having stretchability, the entire nonwoven fabric is soft, and more preferably 70 or more is preferable.
[0018]
The thermoplastic elastomer used in the present invention is a styrene-based thermoplastic elastomer represented by styrene-butadiene-styrene, styrene-hydrogenated butadiene-styrene, styrene-isoprene-styrene, styrene-hydrogenated butadiene, or an ethylene-propylene copolymer. Flexible polyolefin elastomers such as propylene rubber and ethylene / octene copolymer, PBT elastomer represented by trade name Lightflex, polyamide elastomers such as polyamide-ether, polyurethane thermoplastic elastomer, trans-1 / 4 polyisoprene And thermoplastic rubbers typified by syndiotactic-1,2-polybutadiene, ethylene-acrylate copolymers, copolymers of ethylene and propylene with metallocene catalysts, and low density Such as soft resin is preferably such Riechiren, mixtures thereof also convenient.
[0019]
Further, the resin other than the thermoplastic elastomer used for the fiber core component for the non-slip nonwoven fabric is preferably a thermoplastic resin having a melting point in the above range, a good fiber moldability and a fiber material that is usually used. For example, a copolymer of polypropylene or propylene and polyethylene terephthalate are particularly preferable in view of cost.
[0020]
In the present invention, the fibers are partially agglomerated and intertwined so that the nonwoven fabric is bulky, and the elastic nonwoven fabric of the present invention further exhibits rubber elasticity to improve strength. In order to make the non-slip nonwoven fabric of the present invention have a cushioning property, the fibers are fused and bonded to form a lump.
[0021]
Further, in order to give the nonwoven fabric different from the film, that is, the breathable and bulky properties of the nonwoven fabric of the present invention, in particular, the non-slip nonwoven fabric of the present invention is bulky and imparts cushioning properties to promote non-slip properties. In the nonwoven fabric of the present invention, at least a thick fiber having a fiber diameter of 50 to 10 μm is used for fusion bonding by using a thick fiber having a fiber diameter of 50 to 10 μm for the middle layer portion of the product only of the nonwoven fabric, and for bonding with other fiber composition. It is preferable to generate a large amount of lumps to lower the fiber density and produce an irregular appearance, especially in the case of the above-mentioned lamination, when using a part of the nonwoven fabric of the present invention as a thermal bonding component, The fiber diameter is most convenient within the range of 50 to 10 μm, and the basis weight of the portion is conveniently 5 to 15 g / m 2. When the fiber diameter is within this range, if the basis weight is less than 5 g / m 2, the adhesion to the base fabric is weak, and if it exceeds 15 g / m 2, it depends on the fiber material of the partner fiber composition. Problems with film formation are likely to occur. Further, when the fiber diameter of the thick fiber exceeds 50 μm, although it depends on the material of the partner, partial melting of the partner fiber is liable to occur, and if it is less than 10 μm, the fiber accumulation effect on the partner surface is great, Less bite and physical entanglement effect is reduced and adhesive strength is lowered, which is not preferable. Even if the above-mentioned thick fiber exceeding 50 μm can be adequately selected if the other party is selected, there are cases where it is convenient even at about 200 μmφ, so the claims are not limited. I think that even thicker fibers are possible.
[0022]
In the present invention, a composite fiber having a fiber diameter of 200 to 1 μmφ, more preferably 100 to 3 μmφ, and at least a thermoplastic elastomer covering a majority of the fiber surface is blown off in a substantially continuous state by a melt blow technique. It is an integrated non-woven fabric, and the fibers are fused and bonded after ejection from the nozzle to achieve randomness in the fiber orientation direction and increase in unevenness, and the fiber diameter of the middle layer is specified, but the fiber The diameter of the non-slip non-woven fabric is remarkably different depending on the use. Therefore, the fiber diameter of other portions is not limited, but the stretchable non-woven fabric is limited because the relationship between the fiber diameter and equipment is deep.
[0023]
Originally, thicker fibers are better for increasing the unevenness, and the fiber diameter should be determined as necessary. The fiber diameter referred to in the present invention refers to the number average fiber diameter, and the nonwoven fabric of the present invention uses a heat-adhesive conjugate fiber and is arbitrarily partially fused and bonded. Since the dispersion and distribution of the diameter were wide and the fiber diameter was determined by microscopic observation, it was described as a number average. A lump or fiber bundle that was fused and bonded was counted as one.
[0024]
The fiber composition for bonding the non-slip nonwoven fabric of the present invention, when directly heat-bonded in the melt-blowing process, it is convenient to have a coarse mesh considering the escape of hot air, the melt-blown nonwoven fabric of the present invention is made of polyolefin resin In view of its adhesiveness, a composition made of a polyolefin resin is preferable. Needless to say, a polyester-based composition is preferable when a polyester elastomer is used as the surface.
[0025]
For the fiber composition, the resin used in the present invention may be selected in consideration of the type of fiber constituting the fiber, that is, the melting point of the fiber, and acrylic fiber, wool, or vinylon fiber having no melting point or high decomposition temperature. Is also very convenient to use.
[0026]
DETAILED DESCRIPTION OF THE INVENTION
The thermoplastic resin used in the fiber of the present invention is not a high-flow dedicated resin used in the conventional melt-blowing method, but relates to a melt-blown nonwoven fabric of composite fiber having the characteristics that it is a resin having the same melt viscosity as the staple fiber. The non-woven fabric fiber is a composite fiber in which most of the fiber surface is covered with a soft resin component such as an elastomer, and the fibers are partially agglomerated and entangled to form a functional characteristic. It is a composite nonwoven fabric.
[0027]
DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below based on examples. FIG. 1 is an example of a magnified plan view of a composite fiber nonwoven fabric of the present invention having excellent stretch performance in which fibers are partially agglomerated, intertwined and fused, and FIG. 2 is a partially agglomerated fiber. It is an example of the magnified plane view of the composite fiber of the present invention having excellent anti-slip performance in which the nonwoven fabric surface is in an uneven state and the apparent thickness is increased due to the intertwined and fused lump.
[0028]
The fiber cross section of the composite fiber used in the present invention is an example of a fiber cross section in which the fibers of A are referred to as cat eyes, as illustrated in FIGS.
[0029]
One embodiment of the present invention is a sheath-core type, an eccentric sheath-core type, a cat-eye type, or a three-layer structure, which is made of a substantially continuous thermoplastic elastomer having a fiber diameter (d: μm) of 100>d> 3. A composite fiber composed of a part (sheath part 2) in which a majority of the fiber surface is covered with one component and a center part (core part 1) other than that, such as a type composite fiber, and having a Shore A hardness (A) is 70 or more, the majority of the fiber surface is covered with a component having a flow initiation temperature or melting point lower than that of the core component, and each of a plurality of constituent components has a flow initiation temperature or melting point (Tm: ° C.). 60 <Tm <210, its melt fluidity melt flow rate (MFR: g / 10 min; measurement temperature is 230 ° C., weight is 2.169 Kg, according to JIS-K-6760) is 5 <MFR <200, Thermoplastic with Shore A hardness of 50 or more It is a laster resin, and is made by a melt blow method in which fiber is blown off from a spinneret with a hot air, and the composite fiber is partially agglomerated and formed into a flat fiber aggregate in which there are entangled fusion-bonded lumps, and the fiber surface It is a functional composite fiber nonwoven fabric rich in stretch, which is at least fused and / or fused and bonded and integrated with the components covering the majority of the above.
[0030]
Furthermore, the thermoplastic elastomer which is a component covering the majority of the fiber surface is an ethylene copolymer containing at least 20% by mass of octene-1, and the thermoplastic elastomer occupying the center of the fiber is styrene-butadiene. It is preferably a composite fiber nonwoven fabric rich in stretch, which is a styrene thermoplastic elastomer represented by styrene, styrene-hydrogenated butadiene-styrene, and styrene-hydrogenated butadiene.
[0031]
It should be noted that the two components do not necessarily need to be 100% resin, and at least the majority may be included. The diluted thermoplastic resin is preferably a soft resin such as a soft ethylene-propylene copolymer or an ethylene-propylene-butene-1 copolymer.
[0032]
Needless to say, not only the above-mentioned styrenic thermoplastic elastomer but also a copolyester elastomer having a hard segment made of polyester and a soft segment made of polyether, etc. are convenient.
[0033]
In addition, in order to further improve the strength of the nonwoven fabric, the mesh of the suction net of the melt blown nonwoven fabric production facility is shaped on one side, and the convex portion of the mesh is at least pressed and strongly bonded, and the composite fiber nonwoven fabric rich in elasticity It may be. Instead of this, it is naturally convenient to be partly strongly bonded by point bond thermal bonding or the like, but the former is more convenient in consideration of productivity.
[0034]
Furthermore, in practice, there are many cases where composite post-processing such as pressure-sensitive adhesive processing and partial bonding of non-woven fabrics is carried out, and for these applications, the stretchability of the present invention is applied to non-woven fabrics for which a release function is expected. It is preferable to provide a laminated nonwoven fabric so that it can be processed without stretching or shrinking at least when it is combined with other materials.
[0035]
Another embodiment of the present invention has a flow initiation temperature or melting point (Tm: ° C.) of 60 <Tm <210, its melt flowable melt flow rate (MFR: g / 10 min; measurement temperature is 230 ° C., weight is 2 169 Kg, in accordance with JIS-K-6760), 5 <MFR <200, and the thermoplastic elastomer resin having a Shore A hardness of 50 or more covers most of the fiber surface, and the resin occupying the center of the fiber is the elastomer. The melting point is at least 20 ° C. or higher than the flow start temperature, the melting point (TM: ° C.) is 90 <TM <270, the melt flowable melt flow rate (MFR: g / 10 minutes; the measurement temperature is TM ≦ 200 ° C. 230 ° C., TM ≧ 200 ° C. 290 ° C., weight 2.169 kg, according to JIS-K-6760) 5 <MFR <200 Resin, sheath-core type, eccentric sheath-core type, cat-eye type composite fiber, etc., fiber diameter (d: μm) 100>d> 3, substantially continuous, hot air from spinneret It is made by a melt-blowing method in which fibers are blown away in order to form a flat fiber aggregate in which the composite fibers are partially agglomerated, entangled and fused, and at least a component covering the majority of the fiber surface. It is a composite fiber nonwoven fabric having a high anti-slip effect by being fused and / or fused and integrated.
[0036]
In addition, it is easy to directly heat-bond the above-mentioned nonwoven fabric to another fiber composition. In this case, relatively thick fibers in the present invention are first ejected and laminated on the fiber composition for the purpose of bonding. Thereafter, it is very convenient to laminate the fibers of the present invention having a desired fiber diameter.
[0037]
The composite fiber constituting the nonwoven fabric made by the melt-blowing method of the present invention is a sheath-core type, an eccentric sheath-core type, and a core component such as an ellipse or a cat-eye shape as illustrated in FIG. 3-core type as shown in Fig. 3-C and the fiber cross-section in which one component is divided into at least a plurality of components and other components are divided into mandarin orange type, windmill type, etc. It is a fiber that is a mold, and the fiber shape is basically a circular shape such as a circle or an ellipse, but it may be an irregular shape with a rounded corner. Also, the fiber of the present invention is characterized in that a large number of fibers are partially fused and bonded by the components that occupy the majority of the fiber surface, and are unevenly distributed in a bundled state. This is a non-woven fabric, and this fusion-bonded part is a result of the fiber diameter being thicker than the fibers constituting at least other parts, and the case where the fusion-bonding phenomenon is further amplified Many.
[0038]
Another feature of the present invention is that, as described above, the melt viscosity of the thermoplastic resin used matches the viscosity of the resin producing the staple fibers. This is because the present invention avoids various limitations in the process of making a nonwoven fabric such as a roller card, and makes a thinner fiber, a thicker fiber, a fiber that slips badly and does not stick to the card, or a fiber that is easily fused. The main purpose is that. Especially for staple fibers and multifilaments, fiber fusion is fatal. However, this disadvantage is used as an advantage, and composite fibers with a sheath component made of resin that is easy to fuse and bond in fiber production can be directly made into a nonwoven fabric. Is also the main purpose. Therefore, rather than aiming to make the fineness finer by using a low-viscosity resin like conventional melt-blown nonwoven fabrics, it is to create a nonwoven fabric consisting of fibers with the characteristics of staple fiber waist and fiber cross-sectional structure. Therefore, the resin used in the present invention has a melt viscosity similar to that of conventional staples, and only the melting point of the resin used is part conversion of the current single-fiber melt blown nonwoven fabric production equipment, For economic reasons, it is not preferable to raise the temperature of the hot air used unnecessarily, and a limitation of 270 ° C. is provided, but theoretically it is possible even at 350 ° C.
[0039]
The melt fluidity of the resin used in the present invention is in the range of 5 to 200 g / 10 minutes when expressed in terms of the melt flow rate, and the measurement temperature is divided according to whether or not it is sufficiently melted at 230 ° C. The melt fluidity at the melt temperature at the time of melt spinning may not be consistent. The melt fluidity preferred for melt spinning varies depending on the resin, and the most preferred melt fluid state of polyethylene terephthalate or polymethylpentene is around 100 g / 10 minutes, and polypropylene is lower than this. For the above reasons, the thermoplastic resin used in the present invention can be used generally conveniently if the resin used in the conventional staple fiber is devised, and details are not individually mentioned. An example of a resin that is convenient for the core component of the non-slip non-woven fabric described in the paragraphs 9 and after, in addition to the soft resin such as the elastomer described above, is a polyolefin resin having a melting point of 90 to 270 ° C., low Polyester resins including melting point ester copolymers and aliphatic polyesters, polyamide resins such as polyamide and polyimide, and polycarbonate resins can be conveniently used. Examples of these resins include modified resins by polymer alloy, graft polymerization, and low-temperature plasma treatment. it can.
[0040]
The fiber diameter of the composite fiber of the present invention is such that the fiber diameter varies between the fused part and the non-fused part, and the thick part is generally less than 200 μm, and substantially continuous is the fiber for some individual reason. Unless it is broken, it means that the production condition is not intended to be broken.
[0041]
Note that the composite meltblown fiber in the present invention is more advantageous for increasing the bulk by the uneven method, especially when the aggregated and fusion-bonded lump is scattered, and when thick fibers are used, the fiber accumulation is divided into multiple times. Even in the fine fiber layer, in order to avoid unevenness of the fabric weight, it is also preferable to assemble the fibers in a plurality of times as described above.
[0042]
Further, in these fiber accumulations, the fibers are easily aligned in a certain direction by the melt blow method, and therefore, it is preferable to laminate the layers so that they intersect as much as possible. In the present invention, this point is taken into consideration in the equipment.
[0043]
Considering the required weight of each layer as described above, the weight of the nonwoven fabric of the present invention depends on the use, but is preferably 30 to 400 g / m 2, and if it exceeds 400 g / m 2, the hot air penetration is poor and 30 g If it is less than / m 2, it is not convenient because it is not possible to secure unevenness in weight per unit area.
[0044]
The fiber composition described in claim 10 or later of the present invention is advantageously a nonwoven fabric such as a spunbond nonwoven fabric, a melt blown nonwoven fabric, a spunlace nonwoven fabric, a heat bonded nonwoven fabric, a needle punched nonwoven fabric, or a resin impregnated bonded nonwoven fabric. The composite is called a composite composition.
[0045]
In order to make the composite fiber nonwoven fabric of the present invention flame-retardant, for example, a flame retardant stab CGL-116 of Ciba Specialty Chemicals may be added to the resin to obtain a nonwoven fabric. . By performing such a flame retardant treatment, the flame retardant evaluation method JIS. It becomes possible to obtain flame retardant tertiary by L1091, A-1 method. The above-mentioned flame retardant effect agent CGL-116 is a derivative of a Halus stabilizer which is a normal weathering stabilizer, and does not contain environmental hormones or harmful substances even in combination with the Hals stabilizer or other stabilizers. So it is very environmentally friendly. In addition, a spunbonded nonwoven fabric added with at least 0.5 wt% of flame retardant effect agent Flem Stub CGL-116 of Ciba Specialty Chemicals Co., Ltd. is laminated and integrated on at least one side of the composite fiber nonwoven fabric of the present invention. It may be a composite composition.
[0046]
Next, the effects of the present invention will be specifically described with reference to examples and comparative examples. The sheath component according to one embodiment of the present invention is a polyolefin elastomer that is an ethylene copolymer containing at least 20% by mass of octene-1, and the core component is a styrene thermoplastic that is styrene-hydrogenated butadiene-styrene. The melt blown non-woven fabric, which is rich in elasticity of the composite fiber used as the elastomer, and the non-slip non-woven fabric in which the ethylene-acrylic acid methyl ester copolymer and the PBT elastomer are the sheath component and the core component is polypropylene, respectively. It goes without saying that the composite fiber nonwoven fabric and the composite nonwoven fabric can be easily manufactured in the same manner with reference to the examples.
[0047]
【Example】
The composite fiber fiberized by the melt-blowing method of the present invention is a composite of 850 holes with a width of less than 70 cm that can form a composite fiber by extruding individual thermoplastic resins from two extruders and quantitatively supplying them with a gear pump. A nozzle is used to discharge from a row of orifices into a high-speed heating airflow, and at the same time, the airflow is elongated to form a basically continuous fiber, which is accumulated on a net conveyor provided with suction equipment. A composite fiber nonwoven fabric was obtained.
[0048]
In addition, a polypropylene spunbond nonwoven fabric preheated at 140 ° C. is positioned on the conveyor, and thick composite fibers having an average fineness of 6 to 10 dTex (23 to 38 μmφ) are accumulated on the nonwoven fabric with a basis weight of 15 g / m 2, The composite fiber nonwoven fabric of the present invention was also made as a trial by laminating thick fibers or fine fibers having a desired basis weight while varying the accumulation angle. Each layer is accumulated by intersecting at an angle of at least 30 °.
[0049]
The resin used in the present invention is as follows, PP is polypropylene, EO is EG8200 ethylene-octene-1 copolymer of 20% by mass of octene-1, and SE is styrene-hydrogenated butadiene-styrene. Kraton Polymer's G1657 styrenic elastomer, PB is Celanese PBT elastomer light flex 640, PT is polyethylene terephthalate (using a resin with a conventional critical viscosity IV of 0.64), EP is propylene-rich ethylene As the propylene copolymer and DY, Dynalon 1320P manufactured by JSR Corporation was used. However, EP and DY were mixed at a ratio of 45/55. The composite ratio of the sheath and the core component is 1: 1, and the melt-flowable MFR is measured at a temperature of 290 ° C. for PT and 230 ° C. for others, and the unit is g / 10 minutes. The resin whose name is not described in Table 1 is mainly described. In the case of elastomer, the melting point is read as the flow start temperature.
[0050]
[Table 1]

[0051]
(Examples 1-7, Comparative Examples 1-2) The stretchable composite fiber meltblown nonwoven fabric of the present invention was made into a nonwoven fabric under the conditions shown in Table 2 using the resin shown in Table 1 and the above-described steps. The spinning temperature is the nozzle temperature, and is ejected using high-pressure hot air at the same temperature, sucked at a suction amount of 5 times or more of the ejected hot air amount, and accumulated on the conveyor, compared with the examples. An example composite fiber nonwoven fabric was obtained. The tensile test result (SS curve) of the composite fiber nonwoven fabric obtained in Examples 1 and 2 is shown in FIGS.
(This SS curve uses Tensilon UCT-1T manufactured by Orientec Co., Ltd., with load cell rating: 10 kgf, test speed: 300 mm / min, distance between chucks: 10 cm.)
[0052]
Table 2 shows the results of the extension repetition test of Example 1. The fineness in the table is the number average fiber diameter μm, and the fused fiber is excluded. Each fiber layer is at least two times of accumulation, and is expressed by its total weight g / m 2. The unit is 100 μm. However, since PB is a hard polymer, it is indicated by D hardness. D hardness is according to ASTM-D2240 method, as is A hardness.
[0053]
[Table 2]

[0054]
In Comparative Example 1, a DY resin having a Shore A hardness of 39 was used instead of the EO elastomer of Example 1, and the fusion between fibers was so severe that it could not be said to be a non-woven fabric but became a film. Moreover, although the comparative example 2 is Example 8 mentioned later, there was no elasticity.
[0055]
Example 7 is a non-woven fabric obtained by placing the fiber of Example 1 on a conveyor with a PP spunbonded nonwoven fabric of about 7 dTex at a weight of 15 g and melt blown from above, and the laminated nonwoven fabric has the tensile strength of the spunbonded nonwoven fabric. The strength of the spunbonded nonwoven fabric was shown, and these were easily peeled off.
[0056]
(Examples 8 to 10, Comparative Example 3) The non-slip meltblown nonwoven fabric of the present invention comprises the resin of Table 1 and an ethylene-acrylate copolymer EM having a soft methyl acrylate content of 21% by mass and a melting point of 90 ° C. In the same manner as in Example 1, the composite fiber nonwoven fabrics of Examples and Comparative Examples were obtained by converting into a nonwoven fabric under the conditions shown in Table 2 in the above-described steps. Both were non-slip (non-slip) non-woven fabrics and, of course, did not stretch.
[0057]
(Example 11) A composite nonwoven fabric in which the nonwoven fabric of Example 8 was impregnated with acrylic resin of 3dTex fiber of polyethylene terephthalate and bonded directly by melt-blowing on a chemical bond nonwoven fabric having a basis weight of 60 g / m 2 was prepared. The nonwoven fabric was not slipped or slipped from the floor surface even when the nonwoven fabric of Example 8 was placed in contact with the floor surface and the chemical bond nonwoven fabric was kicked and walked.
[0058]
【The invention's effect】
The present invention resides in that a composite fiber using a thermoplastic resin conventionally used in staple fibers is directly made into a non-woven fabric by using a melt-blown fiberization technique, and conventional fibers such as staple fibers and multifilament fibers are used. In the method, a thermoplastic resin that is easily fused can be used positively, which has been a very serious problem, and particularly preferable is a composite fiber using the above-described easily fused resin on the fiber surface. However, by actively utilizing this fusing phenomenon, it was confirmed that the elastomer component, which caused the partial fusing of the fiber during the ejection of the fiber and agglomerated, entangled and fused and bonded, occupied the majority of the fiber surface. It is the melt blown composite fiber nonwoven fabric characterized.
By adopting the configuration as described above, the present invention provides a melt blown functional composite fiber nonwoven fabric rich in stretchability or non-slip property and a composite composition in which this is combined, and is a versatile product. It can be a nonwoven material that can be developed.
[Brief description of the drawings]
FIG. 1 is an enlarged plan view of a functional composite fiber nonwoven fabric of the present invention having excellent stretch performance.
FIG. 2 is an enlarged plan view of the functional composite fiber nonwoven fabric of the present invention having excellent anti-slip performance.
FIG. 3A is a fiber cross-sectional view of a feline eye type composite fiber.
B: Fiber cross-sectional view of a sheath-core type composite fiber.
C: Fiber cross-sectional view of a three-layer composite fiber.
4 is a longitudinal direction SS curve of the stretchable nonwoven fabric of Example 1. FIG.
5 is a transverse direction SS curve of the stretchable nonwoven fabric of Example 1. FIG.
6 is a longitudinal direction SS curve of the stretchable nonwoven fabric of Example 2. FIG.
7 is a transverse direction SS curve of the stretchable nonwoven fabric of Example 2. FIG.
[Explanation of symbols]
1 core component
2 sheath component
3 Lump parts where the composite fibers are partially agglomerated, entangled and melt bonded

Claims (12)

The majority of the fiber surface made by the melt blow method is composed of a composite fiber composed of an elastomer having a Shore A hardness (A) of 50 or more according to ASTM-D2240 method, and the elastomer is a styrene thermoplastic elastomer, ethylene / octene copolymer The composite fibers are discharged from a composite nozzle having a discharge hole interval of less than 1 mm, and the composite fibers are partially in contact with each other during jetting, and are partially aggregated and entangled with each other. Functional composite fiber nonwoven fabric in which a lump is present.   A composite fiber having a fiber surface (d: μm) of a substantially continuous thermoplastic elastomer having a diameter of 100> d> 3 and a majority of the fiber surface covered with one component, and having a Shore A hardness (A) of The majority of the fiber surface is covered with a component having a flow starting temperature or melting point lower than that of the core component other than the component covering the majority of the fiber surface at a temperature of 70 or more. Temperature or melting point (Tm: ° C.) 60 <Tm <210, melt flow rate melt flow rate (MFR: g / 10 min; measurement temperature is 230 ° C., load is 2.169 Kg, according to JIS-K-6760) Is a thermoplastic elastomer resin having a Shore A hardness of 50 or more, and is made by a melt-blowing method in which a fiber is blown off with hot air from a spinneret. Stretching performance, which is a flat fiber aggregate in which agglomerated, entangled and fusion-bonded lumps are present, and at least fusion-bonded and / or melt-bonded and integrated with components covering the majority of the fiber surface The functional composite fiber nonwoven fabric according to claim 1, wherein   The functional composite fiber nonwoven fabric according to claim 1 or 2, wherein the thermoplastic elastomer which is a component covering a majority of the fiber surface is an ethylene copolymer containing at least 20% by mass of octene-1.   Further, the core component other than the component covering the majority of the fiber surface is an elastomer containing at least a majority of a styrene-based thermoplastic elastomer represented by styrene-butadiene-styrene, styrene-hydrogenated butadiene-styrene, and styrene-hydrogenated butadiene. The functional composite fiber nonwoven fabric according to claim 3.   3. The thermoplastic elastomer according to claim 2, wherein the core component other than the component covering the majority of the fiber surface is an elastomer containing at least a majority of a copolyester elastomer having a hard segment as a polyester and a soft segment as a polyether. Functional composite fiber nonwoven fabric.   The functionality according to any one of claims 1 to 5, wherein the mesh of the suction net of the melt blown nonwoven fabric manufacturing facility is formed on one surface thereof, and the convex portion of the mesh is at least pressed and fused and bonded more strongly than the other. Composite fiber nonwoven fabric.   The functional composite fiber nonwoven fabric according to any one of claims 1 to 6 is disposed on a nonwoven fabric expected to have a mold release function, and is capable of being processed without stretching at the time of composite processing with at least another material. A composite composition having a functional composite fiber nonwoven fabric layer.   Flow start temperature or melting point (Tm: ° C.) 60 <Tm <210, melt flowability melt flow rate (MFR: g / 10 min; measurement temperature is 230 ° C., weight is 2.169 Kg, JIS-K-6760 5), the majority of the fiber surface is covered with a thermoplastic elastomer resin having a Shore A hardness of 50 or more, and the resin occupying the center of the fiber has a melting point at least 20 ° C. higher than that of the elastomer, or It is higher than the flow start temperature, its melting point (TM: ° C.) is set to 90 <TM <270, its melt flowable melt flow rate (MFR: g / 10 min; measurement temperature is 230 ° C. when TM ≦ 200 ° C., TM ≧ 200 ° C., 290 ° C., weight is 2.169 Kg, according to JIS-K-6760) is a thermoplastic resin with 5 <MFR <200, sheath core type, eccentric This is a composite fiber that can be selected from a sheath-core type or cat-eye type composite fiber, and has a fiber diameter (d: μm) of 100> d> 3, and is blown with hot air from a spinneret that is substantially continuous, and fiberized A flat fiber aggregate made by a melt-blowing method, in which the composite fiber is partially agglomerated and entangled and fusion-bonded, and a component covering the majority of the fiber surface is at least fusion-bonded and / or 2. The functional composite fiber nonwoven fabric according to claim 1, wherein the functional composite fiber nonwoven fabric is melt-bonded and bonded and integrated to have anti-slip performance.   A composite composition having anti-slip performance, wherein the fiber composition is bonded to at least one surface of the composite fiber nonwoven fabric according to claim 8.   The composite fiber nonwoven fabric according to claim 8 and the fiber composition are bonded to each other by at least fusion bonding and / or melt bonding with a component covering a majority of the fiber surface constituting the composite fiber nonwoven fabric according to claim 8. The composite composition having anti-slip performance according to claim 9 which is integrated.   The functional composite fiber nonwoven fabric in which the composite fiber nonwoven fabric according to claim 1 is flame-retardant.   2. The method for producing a functional composite fiber nonwoven fabric according to claim 1, wherein spinning is performed by a melt blow method using a composite nozzle having a discharge hole interval of less than 1 mm.

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