JP4119261B2 - デンプン及びポリマーを含む多成分繊維 - Google Patents
デンプン及びポリマーを含む多成分繊維 Download PDFInfo
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- JP4119261B2 JP4119261B2 JP2002587683A JP2002587683A JP4119261B2 JP 4119261 B2 JP4119261 B2 JP 4119261B2 JP 2002587683 A JP2002587683 A JP 2002587683A JP 2002587683 A JP2002587683 A JP 2002587683A JP 4119261 B2 JP4119261 B2 JP 4119261B2
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- starch
- fibers
- fiber
- polymer
- multicomponent
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Description
本発明はまた、多成分繊維を含む不織布ウェブ及び使い捨て物品に関する。不織布ウェブはまた、本発明の多成分繊維とブレンドされる他の合成繊維又は天然繊維を含有してもよい。
(デンプン)
本発明は、低コストで天然に生じるポリマーである、デンプンの使用に関する。本発明において使用するデンプンは、十分な紡糸性能及び繊維特性のために必要とされる非構造化デンプンである。用語「熱可塑性デンプン」は、可塑剤を用いて非構造化(destructured)されたデンプンを意味するために使用される。
デンプンと実質的に相溶性の熱可塑性ポリマーもまた、本発明において必要とされる。本明細書で使用する時、用語「実質的に相溶性の」とは、組成物の軟化温度及び/又は融解温度を超える温度に加熱された時、ポリマーが剪断力又は伸張によって混合された後で、デンプンとの実質的に均一な混合物を形成可能であることを意味する。使用される熱可塑性ポリマーは、加熱と同時に流動して加工処理可能な溶融物を形成し、結晶化又はガラス化の結果、再固化することができなければならない。
可塑剤は、デンプンを非構造化し、デンプンを流動可能にするために(すなわち、熱可塑性デンプンを作るために)、本発明において使用することができる。同じ可塑剤をまた、溶融加工処理性を増加させるために使用してもよく、又は2つの単独の可塑剤を使用してもよい。可塑剤はまた、可塑剤によって組成物のガラス転移点が低下することに起因すると考えられる最終製品の可撓性を向上させ得る。可塑剤は、好ましくは、本発明のポリマー成分と実質的に相溶性であるべきであり、その結果、可塑剤は組成物の性質を効果的に改質させ得る。本明細書で使用する時、用語「実質的に相溶性のある」とは、組成物の軟化及び/又は融解温度を超える温度に加熱された時、可塑剤がデンプンとの実質的に均一な混合物を形成できることを意味する。
場合により、他の成分は、紡糸可能なデンプン組成物に組み込まれてもよい。これらの任意成分は、組成物の約50%未満、好ましくは約0.1重量%〜約20重量%、さらに好ましくは約0.1重量%〜約12重量%の量で存在してよい。加工処理性を変えるため及び/又は最終製品の弾性、引張強度、及び弾性率のような物理的特性を変えるために、任意選択的な材料を使用してもよい。他の利益には、酸化安定性を含む安定性、輝度、色、可撓性、弾力性、作業性、加工助剤、粘度調節剤、及び抑臭が挙げられるが、これらに限定されない。非限定的な例としては、塩、スリップ剤、結晶化促進剤又は遅延剤、臭気マスキング剤、架橋剤、乳化剤、界面活性剤、シクロデキストリン、潤滑剤、他の加工助剤、光学的光沢剤、酸化防止剤、難燃剤、染料、顔料、フィラー、タンパク質及びそのアルカリ塩、ワックス、粘着付与樹脂、増量剤、及びこれらの混合物が挙げられる。スリップ剤は、繊維の粘着性又は摩擦係数の低下を促進するために使用できる。また、スリップ剤を、繊維の安定性、特に多湿又は高温における安定性を改良するために使用してもよい。好適なスリップ剤はポリエチレンである。塩もまた、溶融物に添加してもよい。前記塩は、デンプンを可溶化し、変色を減らし、繊維をより水反応性にするか、又は加工助剤として使用するのに役立つ可能性がある。塩は結合剤の溶解性の低下を助ける機能もあるため、溶解しないが、水に入れられるか流された時に、溶解して結合剤の溶解を可能にし、水反応性のより高い製品を作る。塩の非限定的な例としては、塩化ナトリウム、塩化カリウム、硫酸ナトリウム、硫酸アンモニウム、及びこれらの混合物が挙げられる。
本発明の多要素繊維は、多数の異なる形状であってもよい。構成要素は、本明細書で用いる時、物質又は材料の化学種を意味するとして定義される。本明細書で使用する時、多要素繊維は、1超過の化学種又は材料を含有する繊維を意味するように定義される。一般に繊維は、形状において、単成分又は多成分であってもよい。構成成分は、本明細書で用いる時、繊維の別の部分と空間的関係を有する繊維の単独の部分として定義される。用語、多成分は、本明細書で使用する時、お互いに空間的な関係において1つより多くの単独の部分を有する繊維として定義される。用語、多成分は、お互いに空間的関係において2つの単独の部分を有する繊維として定義される二成分を含む。多成分繊維の異なった構成成分は、繊維の断面を横切る実質的に識別可能な区域に配置され、繊維の長さに沿って連続して伸長する。
図1Aは、構成成分Xが中実コアを含み、構成成分Yが連続シースを含むような同一中心のシース−コア形状を示す。
図1Bは、構成成分Xが中実コアを含み、構成成分Yが成形された連続シースを含むようなシース−コア形状を示す。
図1Cは、構成成分Xが中空コアを含み、構成成分Yが連続シースを含むようなシース−コア形状を示す。
図1Dは、構成成分Xが中空コアを含み、構成成分Yが成形された連続シースを含むようなシース−コア形状を示す。
図1Eは、構成成分Xが中実コアを含み、構成成分Yが不連続なシースを含むようなシース−コア形状を示す。
図1Fは、構成成分Xが中実コアを含み、構成成分Yが不連続なシースを含むようなシース−コア形状を示す。
図1Gは、構成成分Xが中空コアを含み、構成成分Yが不連続なシースを含むようなシース−コア形状を示す。
図1Hは、構成成分Xが中空コアを含み、構成成分Yが不連続なシースを含むようなシース−コア形状を示す。
図1Iは、構成成分Xが中実コアを含み、構成成分Yが連続シースを含むような偏心的なシース−コア形状を示す。
図2は、区分されたパイ形状を有する二成分繊維の横断面図を示した概略図である。構成成分X及びYは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
図2Aは、中実の8区分されたパイ形状を示す。
図2Bは、中空の8区分されたパイ形状を示す。この形状は、分裂可能な繊維を製造するのに好適な形状である。
図3は、リボン形状を有する二成分繊維の横断面図を示した概略図である。構成成分X及びYは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
図4は、サイド・バイ・サイド形状を有する二成分繊維の横断面図を示した概略図である。構成成分X及びYは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
図4Aは、サイド・バイ・サイド形状を示す。
図4Bは、曲線的な隣接線を有するサイド・バイ・サイド形状を示す。隣接線は、2つの構成成分が交わるところである。構成成分Yは、構成成分Xよりも多量に存在する。
図4Cは、構成成分Yが構成成分Xの両側に曲線的な隣接線を有して位置しているサイド・バイ・サイド形状である。
図4Dは、構成成分Yが構成成分Xの両側に位置しているサイド・バイ・サイド形状である。
図4Eは、構成成分Yが構成成分の先端に位置している成形されたサイド・バイ・サイド形状である。
図5は、海島形状を有する二成分繊維の横断面図を示した概略図である。構成成分X及びYは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
図5Aは、構成成分Xが構成成分Yによって囲まれた中実の海島形状である。構成成分Xの形状は三角形である。
図5Bは、構成成分Xが構成成分Yによって囲まれた中実の海島形状である。
図5Cは、構成成分Xが構成成分Yによって囲まれた中空の海島形状である。
図6は、リボン形状を有する三成分繊維の横断面図を示した概略図である。構成成分X、Y、及びZは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
図7は、構成成分Xが中実コアを含み、構成成分Yが内側の連続シースを含み、構成成分Zが外側の連続シースを含む、同一中心のシース−コア形状を有する三成分繊維の横断面図を示す。構成成分X、Y、及びZは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
図8は、中実の8区分されたパイ形状を有する多成分繊維の横断面図を示した概略図である。構成成分X、Y、Z、及びWは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
図9は、中実の海島形状を有する三成分繊維の横断面図を示した概略図である。構成成分Xは、構成成分Yを含む単一の島と、構成成分Zを含む多数の島とを取り囲む。構成成分X、Y、及びZは、熱可塑性デンプン、熱可塑性ポリマー、又はこのデンプン及びポリマーのブレンドであってもよい。
「高減衰繊維」は、高ドローダウン比を有する繊維と定義される。全繊維延伸倍率は、最終用途における最終的な繊維直径に対する最大直径の繊維(一般的には毛管出口の直後で生じる)の比として定義される。人造、スパンボンド、又はメルトブロウン法のいずれかによる全繊維ドローダウン比は1.5より大きく、好ましくは5より大きく、より好ましくは10より大きく、最も好ましくは12より大きい。これは触覚特性及び有用な機械的特性を達成するために必要である。
多成分繊維を製造する第1の工程は、配合又は混合工程である。配合工程において、原材料を、典型的には剪断力の下で加熱する。熱の存在下での剪断は、組成物を適切に選択すれば均一な溶融物を生じる。溶融物は、続いて繊維が形成される押出成形機に入れられる。繊維の収集物は、不織布ウェブの形成を生じる熱、圧力、化学的バインダー、機械的なもつれ、及びこれらの組み合わせを用いて互いに組み合わされる。続いて、不織布は物品へと組み立てられる。
配合工程の目的は、デンプン、ポリマー、及び/又は可塑剤を含む均一な溶融組成物を製造することである。構成要素がデンプン又はポリマーのみで、両方は含まないように製造される場合、配合工程は所望の組成物を考慮して改変される。好ましくは、溶融組成物は均一であるが、これは、均一分布が広範囲にわたって見られ、識別可能な領域が観測されないことを意味する。
1.より高い融解温度を有するポリマーを加熱し、その融点を超えて混合する。典型的には、これは、その融解温度よりも30℃〜70℃上である。混合時間は、一般的に約2〜約10分、好ましくはおおよそ5分である。次いで、典型的には、120℃〜140℃までポリマーを冷却する。
2.デンプンは、完全に非構造化されている。このデンプンは、水中に70℃〜100℃の温度で、デンプンの分子量、非構造化デンプンの所望の粘度、及び非構造化可能な時間に依存して、10〜90%のデンプン濃度で溶解することによって非構造化することができる。一般的に、約15分がデンプンを非構造化するのに十分であるが、10〜30分が条件に依存して必要であってもよい。必要に応じて、可塑剤を非構造化デンプンに添加することができる。
3.次いで、工程1の冷却したポリマーと工程2の非構造化デンプンとを混合する。ポリマー及びデンプンは、剪断力を伴って押出成形機又はバッチ混合機中で混合することができる。混合物を、典型的には、約120℃〜140℃まで加熱する。このことにより、水の蒸発が生じる。すべての水を蒸発させることが望ましい場合、混合物をすべての水がなくなるまで混合すべきである。典型的には、この工程における混合は約2〜15分であり、典型的にはほぼ5分である。デンプン及びポリマーの均一なブレンドが形成される。
4.次いで、第2のポリマーを、工程3の均一なブレンドに添加する。この第2のポリマーを、室温で添加してもよく、又は溶融し混合した後に添加してもよい。工程3からの均一なブレンドを、約100℃〜約170℃の温度で混合しつづける。100℃を超える温度が、形成する工程からのいかなる水分も防ぐために必要とされる。可塑剤を、工程2において添加しない場合、ここで添加してもよい。ブレンドを、均一になるまで混合しつづける。目立った領域がないことに注意することによって、これを観察する。混合時間は、一般的に約2〜約10分、通常はほぼ5分である。
本発明は、溶融紡糸の方法を利用する。溶融紡糸では、押出品に質量損失がない。溶融紡糸は、溶媒が揮発又は押出品からの発散によって除去されて質量損失を生じる溶液からの湿式又は乾式紡糸のような他の紡糸とは区別される。
多成分繊維は、種々の接合方法で不織布に変換されてもよい。連続繊維は、産業界で標準的なスパンボンド式技術を用いてウェブに形成でき、一方で短繊維は産業界で標準的なカーディング、エアレイド、又は湿式載置技術を用いてウェブに形成できる。代表的な接合方法には、圧延(圧力及び熱)、通気加熱、機械的なもつれ、流体力学的なもつれ、ニードルパンチ、並びに化学接合及び/又は樹脂接合が挙げられる。圧延、通気熱(thru-air heat)、及び化学的接合は、デンプン及びポリマー多成分繊維のための好ましい接合法である。熱接合可能な繊維は、加圧熱及び通気熱接合方法に必要である。
Claims (13)
- 複数の溶融組成物を紡糸して製造される多成分複合繊維であって、
前記溶融組成物は、非構造化デンプン、500,000g/mol未満の分子量を有する熱可塑性ポリマー、及びこれらの混合物からなる群から選択される材料を含み、
少なくとも一つの溶融組成物は非構造化デンプンを含み、
かつ、いずれも前記溶融組成物の全含水量は1%未満であることを特徴とする多成分繊維。 - 少なくとも1つの前記溶融組成物が、
a.非構造化デンプン、
b.500,000未満の分子量を有する熱可塑性ポリマー、及び
c.可塑剤
を含むことを特徴とする請求項1に記載の多成分複合繊維。 - 少なくとも1つの前記溶融組成物が非構造化デンプンを含み、少なくとも他の溶融組成物は全てが500,000g/mol未満の分子量を有する熱可塑性ポリマーを含むことを特徴とする請求項1に記載の多成分複合繊維。
- 前記繊維が200マイクロメートル未満の直径を有することを特徴とする請求項1から3のいずれか一項に記載の多成分複合繊維。
- 前記繊維が分裂可能であることを特徴とする請求項1から4のいずれか一項に記載の多成分複合繊維。
- 請求項1から5のいずれか一項に記載の多成分複合繊維を含むことを特徴とする不織布ウェブ。
- 複数の溶融組成物を紡糸して製造される多成分複合繊維を含む不織布ウェブであって、前記溶融組成物が、非構造化デンプン、500,000g/mol未満の分子量を有する熱可塑性ポリマー、及びこれらの混合物からなる群から選択される材料を含み、
少なくとも一つの溶融組成物は非構造化デンプンを含み、
かつ、いずれも前記溶融組成物の全含水量は1%未満であることを特徴とする不織布ウェブ。 - 前記多成分複合繊維が、他の合成繊維又は天然繊維とブレンドされ、互いに接合されることを特徴とする請求項6又は7のいずれか一項に記載の不織布ウェブ。
- 請求項6から8のいずれか一項に記載の不織布ウェブを含むことを特徴とする使い捨て物品。
- 請求項1に記載の多成分複合繊維であって、
前記多成分複合繊維がシース−コア形状を有し、
該シースが非構造化デンプン及び可塑剤を含み、該コアが500,000g/mol未満の分子量を有する熱可塑性ポリマーを含むことを特徴とする多成分複合繊維。 - 請求項1に記載の多成分複合繊維であって、
前記多成分複合繊維はシース−コア形状を有し、該シースが500,000g/mol未満の分子量を有する熱可塑性ポリマーを含み、該コアが非構造化デンプン及び可塑剤を含むことを特徴とする多成分複合繊維。 - 請求項1に記載の多成分複合繊維であって、前記非構造化デンプンが少なくとも一つのデンプンと少なくとも一つの可塑剤から得ることができることを特徴とする多成分複合繊維。
- 溶融紡糸により多成分複合繊維を製造する方法であって、
前記溶融組成物が、非構造化デンプン、500,000g/mol未満の分子量を有する熱可塑性ポリマー、及びこれらの混合物からなる群から選択される材料を含み、
少なくとも一つの溶融組成物は非構造化デンプンを含み、
かつ、いずれも前記溶融組成物の全含水量は1%未満であることを特徴とする方法。
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EP1397539B2 (en) | 2011-03-23 |
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US20040197554A1 (en) | 2004-10-07 |
ATE370267T1 (de) | 2007-09-15 |
CA2446107A1 (en) | 2002-11-14 |
DE60221830T2 (de) | 2008-05-08 |
EP1397539A1 (en) | 2004-03-17 |
EP1397539B1 (en) | 2007-08-15 |
US20030104204A1 (en) | 2003-06-05 |
AU2002309684B2 (en) | 2005-07-14 |
DE60221830D1 (de) | 2007-09-27 |
JP2004530058A (ja) | 2004-09-30 |
US6746766B2 (en) | 2004-06-08 |
CA2446107C (en) | 2007-01-16 |
WO2002090631A1 (en) | 2002-11-14 |
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