JP5284889B2 - Fiber products - Google Patents
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- JP5284889B2 JP5284889B2 JP2009149781A JP2009149781A JP5284889B2 JP 5284889 B2 JP5284889 B2 JP 5284889B2 JP 2009149781 A JP2009149781 A JP 2009149781A JP 2009149781 A JP2009149781 A JP 2009149781A JP 5284889 B2 JP5284889 B2 JP 5284889B2
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- 239000000835 fiber Substances 0.000 title claims description 173
- 229920000728 polyester Polymers 0.000 claims description 73
- 239000004745 nonwoven fabric Substances 0.000 claims description 60
- 239000002131 composite material Substances 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 9
- 239000000155 melt Substances 0.000 claims description 8
- 239000004753 textile Substances 0.000 claims description 5
- 239000011358 absorbing material Substances 0.000 claims description 3
- 239000012773 agricultural material Substances 0.000 claims description 3
- 239000011810 insulating material Substances 0.000 claims description 3
- 238000000034 method Methods 0.000 description 17
- 239000003513 alkali Substances 0.000 description 15
- 238000012545 processing Methods 0.000 description 15
- 229920000642 polymer Polymers 0.000 description 14
- 238000009987 spinning Methods 0.000 description 10
- 229920001410 Microfiber Polymers 0.000 description 9
- -1 polyethylene terephthalate Polymers 0.000 description 9
- 238000004090 dissolution Methods 0.000 description 8
- 239000002243 precursor Substances 0.000 description 8
- 239000013585 weight reducing agent Substances 0.000 description 8
- 238000005259 measurement Methods 0.000 description 7
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- 230000000704 physical effect Effects 0.000 description 6
- 230000004580 weight loss Effects 0.000 description 6
- 239000002202 Polyethylene glycol Substances 0.000 description 5
- 229920001223 polyethylene glycol Polymers 0.000 description 5
- 229920000139 polyethylene terephthalate Polymers 0.000 description 5
- 239000005020 polyethylene terephthalate Substances 0.000 description 5
- 238000010998 test method Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 239000007864 aqueous solution Substances 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000002788 crimping Methods 0.000 description 3
- 238000000605 extraction Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 238000002074 melt spinning Methods 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 229920000747 poly(lactic acid) Polymers 0.000 description 3
- 239000004626 polylactic acid Substances 0.000 description 3
- 238000011946 reduction process Methods 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 239000004953 Aliphatic polyamide Substances 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 229920003231 aliphatic polyamide Polymers 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical class OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- XSTXAVWGXDQKEL-UHFFFAOYSA-N Trichloroethylene Chemical group ClC=C(Cl)Cl XSTXAVWGXDQKEL-UHFFFAOYSA-N 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 239000012670 alkaline solution Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000000306 component Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000004043 dyeing Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000007850 fluorescent dye Substances 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002121 nanofiber Substances 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 229920000233 poly(alkylene oxides) Polymers 0.000 description 1
- 229920001515 polyalkylene glycol Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 1
- 230000003449 preventive effect Effects 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- UBOXGVDOUJQMTN-UHFFFAOYSA-N trichloroethylene Natural products ClCC(Cl)Cl UBOXGVDOUJQMTN-UHFFFAOYSA-N 0.000 description 1
- 229920003169 water-soluble polymer Polymers 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
Landscapes
- Multicomponent Fibers (AREA)
- Nonwoven Fabrics (AREA)
Description
本発明は、極細ポリエステル繊維を含み、かつ地合いが均一な乾式不織布、および該乾式不織布を用いてなる繊維製品に関する。 The present invention relates to a dry nonwoven fabric containing ultrafine polyester fibers and having a uniform texture, and a fiber product using the dry nonwoven fabric.
従来、フィルター用途やワイピング用途などでは、不織布の密度を低くする必要があるため、主として、ニードルパンチ不織布、スパンレース不織布、エアレイド不織布などの乾式不織布が使用されてきた。また、かかる乾式不織布において、フィルター性能（捕集効率やダスト保持量、寿命）やワイピング性能を高めるために、極細繊維と比較的汎用的な繊度を有する繊維とを組合わせることが提案されている（例えば、特許文献１参照）。
他方、最近ではナノファイバーと称せられる、単繊維径が極めて小さい極細繊維の研究開発が盛んに行われている（例えば、特許文献２、特許文献３参照）。
Conventionally, dry non-woven fabrics such as needle punched non-woven fabrics, spunlaced non-woven fabrics, and airlaid non-woven fabrics have been mainly used because it is necessary to reduce the density of the non-woven fabrics in filter applications and wiping applications. In addition, in such dry nonwoven fabrics, it has been proposed to combine ultrafine fibers with fibers having a relatively general fineness in order to improve filter performance (collection efficiency, dust retention, life) and wiping performance. (For example, refer to Patent Document 1).
On the other hand, recently, research and development of ultrafine fibers having a very small single fiber diameter, which are referred to as nanofibers, have been actively conducted (for example, see Patent Document 2 and Patent Document 3).
このような極細繊維を用いて乾式不織布を得ると、さらにフィルター性能やワイピング性能をある程度高めることが可能であるが、極細繊維を用いて乾式不織布を得る際、極細繊維の分散性が低いため不織布の地合いが悪くなり、フィルター性能やワイピング性能の点で改善の余地があることが判明した。 When a dry nonwoven fabric is obtained using such ultrafine fibers, it is possible to further improve the filter performance and wiping performance to some extent. However, when obtaining a dry nonwoven fabric using ultrafine fibers, the nonwoven fabric has a low dispersibility. It turned out that there was room for improvement in terms of filter performance and wiping performance.
本発明は上記の背景に鑑みなされたものであり、その目的は、極細ポリエステル繊維を含み、かつ地合いが均一な乾式不織布、および該乾式不織布を用いてなる繊維製品を提供することにある。 The present invention has been made in view of the above-described background, and an object thereof is to provide a dry nonwoven fabric containing ultrafine polyester fibers and having a uniform texture, and a fiber product using the dry nonwoven fabric.
本発明者は上記の課題を達成するため鋭意検討した結果、特定の繊径を有する極細ポリエステル繊維と、特定の繊径を有するポリエステル繊維とを用いて乾式不織布を得ると、均一な地合いを有する乾式不織布が得られることを見出し、さらに鋭意検討を重ねることにより本発明を完成するに至った。 As a result of intensive studies to achieve the above-mentioned problems, the present inventor has a uniform texture when a dry nonwoven fabric is obtained using an ultrafine polyester fiber having a specific fiber diameter and a polyester fiber having a specific fiber diameter. It discovered that a dry-type nonwoven fabric was obtained, and also came to complete this invention by repeating earnest examination.
かくして、本発明によれば「目付けが１００〜１０００ｇ／ｍ２の乾式不織布であって、ポリエステルからなり単繊維径ＤＡが５００〜１０００ｎｍであるポリエステル繊維Ａと、ポリエステルからなり単繊維径（ＤＢ）が１０〜１００μｍであるポリエステル繊維Ｂとが前者／後者の重量比３／９７〜７０／３０で含まれ、かつ機械的に絡合処理が施されていることを特徴とする乾式不織布を用いてなる、ワイパー、フィルター、研磨材、断熱材、吸音材、車両内装材、土木用資材、および農業用資材からなる群より選択されるいずれかの繊維製品。」が提供される。 Thus, according to the present invention, “a dry nonwoven fabric having a basis weight of 100 to 1000 g / m 2 , which is made of polyester and has a single fiber diameter DA of 500 to 1000 nm, and a single fiber diameter (DB) made of polyester. Using a dry nonwoven fabric characterized in that polyester fiber B is 10-100 μm in weight ratio of 3/97 to 70/30 of the former / the latter and mechanically entangled. A fiber product selected from the group consisting of a wiper, a filter, an abrasive, a heat insulating material, a sound absorbing material, a vehicle interior material, a civil engineering material, and an agricultural material .
その際、前記ポリエステル繊維Ａにおいて、単繊維径（ＤＡ）ｎｍに対する繊維長（ＬＡ）ｎｍの比（ＬＡ／ＤＡ）が３００００〜１４００００の範囲内であることが好ましい。また、前記ポリエステル繊維Ｂの繊維長（ＬＢ）が３０〜１００ｍｍの範囲内にあることが好ましい。また、前記ポリエステル繊維Ａおよびポリエステル繊維Ｂに捲縮が付与されていることが好ましい。また、前記ポリエステル繊維Ａが、島成分と海成分とからなる海島型複合繊維の海成分を溶解除去したものであることが好ましい。また、前記絡合処理がニードルパンチ機によるものであることが好ましい。 In that case, in the said polyester fiber A, it is preferable that ratio (LA / DA) of fiber length (LA) nm with respect to single fiber diameter (DA) nm exists in the range of 30000-140000. Moreover, it is preferable that the fiber length (LB) of the said polyester fiber B exists in the range of 30-100 mm. Moreover, it is preferable that the polyester fiber A and the polyester fiber B are crimped. Moreover, it is preferable that the said polyester fiber A melt | dissolves and removes the sea component of the sea island type composite fiber which consists of an island component and a sea component. Moreover, it is preferable that the said entanglement process is a thing by a needle punch machine.
本発明によれば、極細ポリエステル繊維を含み、かつ地合いが均一な乾式不織布、および該乾式不織布を用いてなる繊維製品が得られる。 ADVANTAGE OF THE INVENTION According to this invention, the dry nonwoven fabric which contains ultra-fine polyester fiber and has a uniform texture, and the fiber product using this dry nonwoven fabric are obtained.
以下、本発明の実施の形態について詳細に説明する。
本発明において、ポリエステル繊維Ａの単繊維径が５００〜１０００ｎｍの範囲内であることが肝要である。該単繊維径が５００ｎｍ未満では、ポリエステル繊維Ａ同士が擬似膠着しやすく均一分散しにくいため、フィルターやワイピング材などの本来の性能が得られず好ましくない。逆に、該該単繊維径が１０００ｎｍより大きいと、極細ポリエステル繊維としての効果が低くなり、フィルターやワイピング材などしての性能向上が不十分となるため好ましくない。なお、単繊維の断面形状が丸断面以外の異型断面である場合には外接円の直径を単繊維径とする。また、単繊維径は、透過型電子顕微鏡で繊維の横断面を撮影することにより測定が可能である。
Hereinafter, embodiments of the present invention will be described in detail.
In the present invention, it is important that the single fiber diameter of the polyester fiber A is in the range of 500 to 1000 nm. When the single fiber diameter is less than 500 nm, the polyester fibers A are apt to be pseudo-glue and difficult to uniformly disperse, which is not preferable because the original performance of a filter, a wiping material, or the like cannot be obtained. On the contrary, if the single fiber diameter is larger than 1000 nm, the effect as an ultrafine polyester fiber is lowered, and the performance improvement as a filter or wiping material is insufficient, which is not preferable. In addition, when the cross-sectional shape of the single fiber is an atypical cross section other than the round cross section, the diameter of the circumscribed circle is defined as the single fiber diameter. The single fiber diameter can be measured by photographing the cross section of the fiber with a transmission electron microscope.
また、前記ポリエステル繊維Ａにおいて、単繊維径（ＤＡ）ｎｍに対する繊維長（ＬＡ）ｎｍの比（ＬＡ／ＤＡ）が３００００〜１４００００（より好ましくは４００００〜１０００００）の範囲内であることが好ましい。該比（ＬＡ／ＤＡ）が３００００未満では、繊維長が短くなり過ぎるため、他の繊維との絡みが小さくなり、繊維が脱落する可能性が高くなるおそれがある。逆に、該該比（ＬＡ／ＤＡ）が１４００００を越える場合、繊維長が長くなりすぎ、極細ポリエステル繊維Ａ自身の絡みが大きくなり、均一分散が阻害されるおそれがある。 Moreover, in the said polyester fiber A, it is preferable that ratio (LA / DA) of fiber length (LA) nm with respect to single fiber diameter (DA) nm exists in the range of 30000-140000 (more preferably 40000-100,000). When the ratio (LA / DA) is less than 30000, the fiber length becomes too short, so that the entanglement with other fibers becomes small, and the possibility that the fibers fall off increases. On the other hand, when the ratio (LA / DA) exceeds 140000, the fiber length becomes too long, the entanglement of the ultrafine polyester fiber A itself becomes large, and the uniform dispersion may be inhibited.
前記ポリエステル繊維Ａを形成するポリエステルの種類としては、ポリエチレンテレフタレートやポリトリメチレンテレフタレート、ポリブチレンテレフタレート、ステレオコンプレックスポリ乳酸、ポリ乳酸、第３成分を共重合させたポリエステルなどが好ましく例示される。 Preferred examples of the polyester forming the polyester fiber A include polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, stereocomplex polylactic acid, polylactic acid, and polyester obtained by copolymerizing a third component.
前記のようなポリエステル繊維Ａの製造方法としては特に限定されないが、国際公開第２００５／０９５６８６号パンフレットに開示された方法が好ましい。すなわち、単繊維径およびその均一性の点で、ポリエステルポリマーからなりかつその島径（Ｄ）が５００〜１０００ｎｍである島成分と、前記のポリエステルポリマーよりもアルカリ水溶液易溶解性ポリマー（以下、「易溶解性ポリマー」ということもある。）からなる海成分とを有する複合繊維にアルカリ減量加工を施し、前記海成分を溶解除去したものであることが好ましい。なお、前記島径は、透過型電子顕微鏡で繊維の横断面を撮影することにより測定が可能である。なお、島の形状が丸断面以外の異型断面である場合には、前記の島径（Ｄ）は、その外接円の直径を用いる。 Although it does not specifically limit as a manufacturing method of the above polyester fiber A, The method disclosed by the international publication 2005/095686 pamphlet is preferable. That is, in terms of single fiber diameter and uniformity thereof, an island component composed of a polyester polymer and having an island diameter (D) of 500 to 1000 nm, and an alkaline aqueous solution-soluble polymer (hereinafter, “ It is preferable that the composite fiber having a sea component composed of “easily soluble polymer”) is subjected to an alkali weight reduction process, and the sea component is dissolved and removed. The island diameter can be measured by photographing a cross section of the fiber with a transmission electron microscope. In addition, when the shape of the island is an atypical cross section other than a round cross section, the diameter of the circumscribed circle is used as the island diameter (D).
ここで、海成分を形成するアルカリ水溶液易溶解性ポリマーの、島成分を形成するポリエステルポリマーに対する溶解速度比が２００以上（好ましくは３００〜３０００）であると、島分離性が良好となり好ましい。溶解速度が２００倍未満の場合には、繊維断面中央部の海成分を溶解する間に、分離した繊維断面表層部の島成分が、繊維径が小さいために溶解されるため、海相当分が減量されているにもかかわらず、繊維断面中央部の海成分を完全に溶解除去できず、島成分の太さ斑や島成分自体の溶剤侵食につながり、均一な繊維径の超極細繊維が得ることができないおそれがある。 Here, it is preferable that the dissolution rate ratio of the aqueous alkali-soluble polymer that forms the sea component to the polyester polymer that forms the island component is 200 or more (preferably 300 to 3000) because the island separability is good. When the dissolution rate is less than 200 times, the island component of the separated fiber cross-section surface layer is dissolved because the fiber diameter is small while the sea component in the center of the fiber cross-section is dissolved. Despite being reduced in weight, the sea component at the center of the fiber cross section cannot be completely dissolved and removed, leading to thick spots on the island component and solvent erosion of the island component itself, resulting in ultra-fine fibers with a uniform fiber diameter. There is a risk that it will not be possible.
海成分を形成する易溶解性ポリマーとしては、特に繊維形成性の良いポリエステル類、脂肪族ポリアミド類、ポリエチレンやポリスチレン等のポリオレフィン類を好ましい例としてあげることができる。更に具体例を挙げれば、アルカリ水溶液易溶解性ポリマーとして、ポリ乳酸、超高分子量ポリアルキレンオキサイド縮合系ポリマー、ポリアルキレングリコール系化合物と５−ナトリウムスルホイソフタル酸の共重合ポリエステルが最適である。ここでアルカリ水溶液とは、水酸化カリウム、水酸化ナトリウム水溶液などを言う。これ以外にも、ナイロン６やナイロン６６等の脂肪族ポリアミドに対するギ酸、ポリスチレンに対するトリクロロエチレン等やポリエチレン（特に高圧法低密度ポリエチレンや直鎖状低密度ポリエチレン）に対する熱トルエンやキシレン等の炭化水素系溶剤、ポリビニルアルコールやエチレン変性ビニルアルコール系ポリマーに対する熱水を例として挙げることができる。 Preferable examples of the easily soluble polymer forming the sea component include polyesters, aliphatic polyamides, and polyolefins such as polyethylene and polystyrene, which are particularly good in fiber formation. As specific examples, polylactic acid, an ultrahigh molecular weight polyalkylene oxide condensation polymer, and a copolymerized polyester of polyalkylene glycol compound and 5-sodium sulfoisophthalic acid are optimal as the alkaline water soluble polymer. Here, the alkaline aqueous solution refers to potassium hydroxide, sodium hydroxide aqueous solution and the like. Besides these, hydrocarbon solvents such as hot toluene and xylene for formic acid for aliphatic polyamides such as nylon 6 and nylon 66, trichloroethylene for polystyrene, and polyethylene (especially high-pressure low-density polyethylene and linear low-density polyethylene). Examples thereof include hot water for polyvinyl alcohol and ethylene-modified vinyl alcohol polymers.
ポリエステル系ポリマーの中でも、５−ナトリウムスルホイソフタル酸６〜１２モル％と分子量４０００〜１２０００のポリエチレングリコールを３〜１０重量％共重合させた固有粘度が０．４〜０．６のポリエチレンテレフタレート系共重合ポリエステルが好ましい。ここで、５−ナトリウムスルホイソフタル酸は親水性と溶融粘度向上に寄与し、ポリエチレングリコール（ＰＥＧ）は親水性を向上させる。また、ＰＥＧは分子量が大きいほど、その高次構造に起因すると考えられる親水性増加作用があるが、反応性が悪くなってブレンド系になるため、耐熱性や紡糸安定性の面で問題が生じる可能性がある。また、共重合量が１０重量％以上になると、溶融粘度低下作用があるので、好ましくない。 Among polyester polymers, polyethylene terephthalate copolymer having an intrinsic viscosity of 0.4 to 0.6 obtained by copolymerizing 6 to 12 mol% of 5-sodium sulfoisophthalic acid and 3 to 10% by weight of polyethylene glycol having a molecular weight of 4000 to 12000. Polymerized polyester is preferred. Here, 5-sodium sulfoisophthalic acid contributes to improving hydrophilicity and melt viscosity, and polyethylene glycol (PEG) improves hydrophilicity. In addition, PEG has a hydrophilicity increasing action that is considered to be due to its higher-order structure as the molecular weight increases. However, since the reactivity becomes poor and a blend system is produced, problems arise in terms of heat resistance and spinning stability. there is a possibility. On the other hand, if the copolymerization amount is 10% by weight or more, there is an effect of decreasing the melt viscosity, which is not preferable.
一方、島成分を形成するポリエステルポリマーとしては、前述のとおりである。なお、海成分を形成するポリマーおよび島成分を形成するポリマーについて、製糸性および抽出後の極細繊維の物性に影響を及ぼさない範囲で、必要に応じて、有機充填剤、酸化防止剤、熱安定剤、光安定剤、難燃剤、滑剤、帯電防止剤、防錆剤、架橋剤、発泡剤、蛍光剤、表面平滑剤、表面光沢改良剤、フッ素樹脂等の離型改良剤、等の各種添加剤を含んでいても差しつかえない。 On the other hand, the polyester polymer forming the island component is as described above. In addition, for the polymer that forms the sea component and the polymer that forms the island component, organic fillers, antioxidants, and heat-stable as necessary, as long as they do not affect the physical properties of the fine fiber after extraction. Various additives such as additives, light stabilizers, flame retardants, lubricants, antistatic agents, rust preventives, crosslinking agents, foaming agents, fluorescent agents, surface smoothing agents, surface gloss improvers, mold release improvers such as fluororesins, etc. Even if it contains an agent, it is acceptable.
前記の海島型複合繊維において、溶融紡糸時における海成分の溶融粘度が島成分ポリマーの溶融粘度よりも大きいことが好ましい。かかる関係にある場合には、海成分の複合重量比率が４０％未満と少なくなっても、島同士が接合したり、島成分の大部分が接合して海島型複合繊維とは異なるものになり難い。 In the sea-island type composite fiber, it is preferable that the melt viscosity of the sea component at the time of melt spinning is larger than the melt viscosity of the island component polymer. In such a relationship, even if the composite weight ratio of the sea component is less than 40%, the islands are joined together, or the majority of the island components are joined to be different from the sea-island type composite fiber. hard.
好ましい溶融粘度比（海／島）は、１．１〜２．０、特に１．３〜１．５の範囲である。この比が１．１倍未満の場合には溶融紡糸時に島成分が接合しやすくなり、一方２．０倍を越える場合には、粘度差が大きすぎるために紡糸調子が低下しやすい。 A preferred melt viscosity ratio (sea / island) is in the range of 1.1 to 2.0, especially 1.3 to 1.5. If this ratio is less than 1.1 times, the island components are likely to be joined during melt spinning, whereas if it exceeds 2.0 times, the viscosity difference is too large and the spinning tone tends to be lowered.
次に島数は、１００以上（より好ましくは３００〜１０００）であることが好ましい。また、その海島複合重量比率（海：島）は、２０：８０〜８０：２０の範囲が好ましい。かかる範囲であれば、島間の海成分の厚みを薄くすることができ、海成分の溶解除去が容易となり、島成分の極細繊維への転換が容易になるので好ましい。ここで海成分の割合が８０％を越える場合には海成分の厚みが厚くなりすぎ、一方２０％未満の場合には海成分の量が少なくなりすぎて、島間に接合が発生しやすくなる。 Next, the number of islands is preferably 100 or more (more preferably 300 to 1000). The sea-island composite weight ratio (sea: island) is preferably in the range of 20:80 to 80:20. Within such a range, the thickness of the sea component between the islands can be reduced, the sea component can be easily dissolved and removed, and the conversion of the island component into ultrafine fibers is facilitated. Here, when the proportion of the sea component exceeds 80%, the thickness of the sea component becomes too thick. On the other hand, when the proportion is less than 20%, the amount of the sea component becomes too small, and joining between islands is likely to occur.
溶融紡糸に用いられる口金としては、島成分を形成するための中空ピン群や微細孔群を有するものなど任意のものを用いることができる。例えば、中空ピンや微細孔より押し出された島成分とその間を埋める形で流路を設計されている海成分流とを合流し、これを圧縮することにより海島断面が形成されるといった紡糸口金でもよい。吐出された海島型複合繊維は冷却風により固化され、所定の引き取り速度に設定した回転ローラーあるいはエジェクターにより引き取られ、未延伸糸を得る。この引き取り速度は特に限定されないが、２００〜５０００ｍ／分であることが望ましい。２００ｍ／分以下では生産性が悪い。また、５０００ｍ／分以上では紡糸安定性が悪い。 As the die used for melt spinning, an arbitrary one such as a hollow pin group or a fine hole group for forming an island component can be used. For example, even in a spinneret where an island component extruded from a hollow pin or a fine hole and a sea component flow designed to fill the gap between them are merged and compressed, a sea island cross section is formed. Good. The discharged sea-island type composite fiber is solidified by cooling air and taken up by a rotating roller or an ejector set at a predetermined take-up speed to obtain an undrawn yarn. The take-up speed is not particularly limited, but is preferably 200 to 5000 m / min. Productivity is poor at 200 m / min or less. Also, spinning stability is poor at 5000 m / min or more.
得られた未延伸糸は、海成分を抽出後に得られる超極細繊維の用途・目的に応じて、そのままカット工程あるいはその後の抽出工程に供してもよいし、目的とする強度・伸度・熱収縮特性に合わせるために、延伸工程や熱処理工程を経由して、カット工程あるいはその後の抽出工程に供することができる。延伸工程は紡糸と延伸を別ステップで行う別延方式でもよいし、一工程内で紡糸後直ちに延伸を行う直延方式を用いてもかまわない。 The obtained undrawn yarn may be subjected to the cutting process or the subsequent extraction process as it is, depending on the use / purpose of the ultrafine fiber obtained after extracting the sea component, or may have the desired strength / elongation / heat. In order to match the shrinkage characteristics, it can be subjected to a cutting step or a subsequent extraction step via a stretching step or a heat treatment step. The stretching process may be a separate stretching method in which spinning and stretching are performed in separate steps, or a straight stretching method in which stretching is performed immediately after spinning in one process may be used.
次に、かかる複合繊維を、島径（Ｄ）に対する繊維長（Ｌ）の比（Ｌ／Ｄ）が前記の範囲内となるようにカットした後、アルカリ減量加工を施すことにより、前記海成分を溶解除去する。かかるカットは、未延伸糸または延伸糸をそのまま、またいは数十本〜数百万本単位に束ねたトウにしてギロチンカッターやロータリーカッターなどでカットすることが好ましい。 Next, after cutting such a composite fiber so that the ratio (L / D) of the fiber length (L) to the island diameter (D) is within the above range, the sea component is obtained by subjecting to an alkali weight reduction process. Is dissolved and removed. Such cutting is preferably carried out by using a guillotine cutter, a rotary cutter, or the like with undrawn yarn or drawn yarn as it is or with a tow bundled in units of tens to millions.
前記のアルカリ減量加工は、不織布を製造後に行うことが好ましいが、不織布の製造前であってもよい。かかるアルカリ減量加工において、繊維とアルカリ液の比率（浴比）は０．１〜５％である事が好ましく、さらには０．４〜３％である事が好ましい。０．１％未満では繊維とアルカリ液の接触は多いものの、排水等の工程性が困難となるおそれがある。一方、５％以上では繊維量が多過ぎるため、アルカリ減量加工時に繊維同士の絡み合いが発生するおそれがある。なお、浴比は下記式にて定義する。
浴比（％）＝（繊維質量（ｇｒ）／アルカリ水溶液質量（ｇｒ）×１００）
The alkali weight loss processing is preferably performed after the nonwoven fabric is manufactured, but may be performed before the nonwoven fabric is manufactured. In such alkali weight reduction processing, the ratio of fiber to alkaline solution (bath ratio) is preferably 0.1 to 5%, more preferably 0.4 to 3%. If it is less than 0.1%, the contact between the fiber and the alkali liquid is large, but the processability such as drainage may be difficult. On the other hand, if the amount is 5% or more, the amount of fibers is too large, and there is a risk that fibers will be entangled during alkali weight reduction processing. The bath ratio is defined by the following formula.
Bath ratio (%) = (Fiber mass (gr) / Alkaline aqueous solution mass (gr) × 100)
また、アルカリ減量加工の処理時間は５〜６０分である事が好ましく、さらには１０〜３０分である事が好ましい。５分未満ではアルカリ減量が不十分となるおそれがある。一方、６０分以上では島成分までも減量されるおそれがある。
また、アルカリ減量加工において、アルカリ濃度は２％〜１０％である事が好ましい。２％未満では、アルカリ不足となり、減量速度が極めて遅くなるおそれがある。一方、１０％を越えるとアルカリ減量が進みすぎ、島部分まで減量されるおそれがある。
Moreover, it is preferable that the processing time of an alkali weight reduction process is 5 to 60 minutes, Furthermore, it is preferable that it is 10 to 30 minutes. If it is less than 5 minutes, the alkali weight loss may be insufficient. On the other hand, in the case of 60 minutes or more, the island component may be reduced.
In the alkali weight reduction processing, the alkali concentration is preferably 2% to 10%. If it is less than 2%, the alkali is insufficient, and the weight loss rate may be extremely slow. On the other hand, if it exceeds 10%, the weight loss of alkali proceeds too much and there is a risk that the weight may be reduced to the island portion.
本発明において、ポリエステル繊維Ｂの単繊維径ＤＢが１０〜１００μｍの範囲内であることが肝要である。該単繊維径ＤＢが１０μｍ未満では、不織布を製造する際の開繊工程において、ポリエステル繊維Ｂ同士が固まりになったり、均一分散性が得られないおそれがあり好ましくない。逆に、該単繊維径ＤＢが１００μｍよりも大きいと、不織布の地合いが悪くなるおそれがあり好ましくない。なお、単繊維の断面形状が丸断面以外の異型断面である場合には外接円の直径を単繊維径とする。また、単繊維径は、透過型電子顕微鏡で繊維の横断面を撮影することにより測定が可能である。 In the present invention, it is important that the single fiber diameter DB of the polyester fiber B is in the range of 10 to 100 μm. If the single fiber diameter DB is less than 10 μm, the polyester fibers B may be hardened in the fiber opening step when the nonwoven fabric is produced, and uniform dispersibility may not be obtained, which is not preferable. On the contrary, if the single fiber diameter DB is larger than 100 μm, the texture of the nonwoven fabric may be deteriorated, which is not preferable. In addition, when the cross-sectional shape of the single fiber is an atypical cross section other than the round cross section, the diameter of the circumscribed circle is defined as the single fiber diameter. The single fiber diameter can be measured by photographing the cross section of the fiber with a transmission electron microscope.
前記ポリエステル繊維Ｂの繊維長（ＬＢ）が３０〜１００ｍｍの範囲内にあることが好ましい。該繊維長が３０ｍｍ未満では、開繊工程での操業性が悪くなるおそれがある。逆に、該繊維長が１００ｍｍを越えると、繊維同士の絡みが大きくなるおそれがある。 It is preferable that the fiber length (LB) of the said polyester fiber B exists in the range of 30-100 mm. If the fiber length is less than 30 mm, the operability in the opening process may be deteriorated. Conversely, when the fiber length exceeds 100 mm, the entanglement between the fibers may increase.
本発明の乾式不織布は、例えば以下の製造方法により製造することができる。まず、前記のポリエステル繊維Ａまたはその前駆体（海島型複合繊維）と、前記のポリエステル繊維Ｂとを、ポリエステル繊維Ａ（海島型複合繊維の海成分を溶解除去した後の重量）とポリエステル繊維Ｂとの重量比が（前者／後者）３／９７〜７０／３０の範囲内となるように用意する。ここで、ポリエステル繊維Ａの重量割合が該重量比よりも小さいと、フィルター性能やワイピング性能の性能向上が不十分となり好ましくない。逆に、ポリエステル繊維Ａの重量割合が該重量比よりも大きいと、ポリエステル繊維Ａ同士の絡みや繊維脱落の可能性が高くなり好ましくない。なお、不織布全重量に対して１０重量％以下であれば、他の繊維をも用いてもよい。 The dry nonwoven fabric of this invention can be manufactured with the following manufacturing methods, for example. First, the polyester fiber A or a precursor thereof (sea-island type composite fiber) and the polyester fiber B are mixed with the polyester fiber A (weight after dissolving and removing sea components of the sea-island type composite fiber) and the polyester fiber B. Is prepared so that the weight ratio thereof falls within the range of 3/97 to 70/30 (the former / the latter). Here, when the weight ratio of the polyester fiber A is smaller than the weight ratio, the performance improvement of the filter performance and the wiping performance is insufficient, which is not preferable. On the contrary, when the weight ratio of the polyester fiber A is larger than the weight ratio, the entanglement of the polyester fibers A and the possibility of the fiber dropping are increased, which is not preferable. In addition, as long as it is 10 weight% or less with respect to the total weight of a nonwoven fabric, you may use another fiber.
また、前記のポリエステル繊維Ａまたはその前駆体（海島型複合繊維）と、前記のポリエステル繊維Ｂとが、捲縮を施された捲縮繊維であると、繊維が絡合しやすく好ましい。その際、かかる捲縮を施す方法としては機械捲縮など従来公知の方法でよい。 In addition, it is preferable that the polyester fiber A or a precursor thereof (sea-island type composite fiber) and the polyester fiber B are crimped crimped fibers that are easily entangled. At this time, as a method of performing such crimping, a conventionally known method such as mechanical crimping may be used.
次いで、比較的長い短繊維を針の付いたローラーを用いて繊維を開繊混合するカード法や開繊された繊維をエアーによってウェブを積層するランドウェーバー等によりウェブを形成した後、機械的に絡合処理を施すことにより、その際、繊維の固定方法としては、ニードルによる繊維同士の絡み合い（ニードルパンチ法）、高圧水流による繊維同士の絡み合い（スパンレース法）等を適宜用いることが出来る。なかでも、ニードルパンチ機を用いたニードルパンチ法が好ましい。 Next, after forming a web by a card method in which fibers are opened and mixed using a roller with a needle with relatively long short fibers, or a land weber that laminates the opened fibers by air, mechanically By performing the entanglement treatment, as a method for fixing the fibers, entanglement between the fibers by the needle (needle punch method), entanglement between the fibers by the high-pressure water flow (spun lace method), or the like can be used as appropriate. Of these, the needle punch method using a needle punch machine is preferred.
次いで、必要に応じて、前述のようにアルカリ減量加工を施すことにより、海島型複合繊維の海成分を溶解除去することにより、乾式不織布が得られる。
かくして得られた乾式不織布において、その目付けが１００〜１０００ｇ／ｍ２（より好ましくは１２０〜３００ｇ／ｍ２）の範囲内であることが肝要である。該目付けが１００ｇ／ｍ２未満では、フィルター性能やワイピング性能などの性能が十分に得られず好ましくない。逆に、該目付けが１０００ｇ／ｍ２よりも大きいと、高圧水流やニードルにより繊維を絡み合せる際に繊維同士の絡み合いが不十分となったり、アルカリ減量加工で海島型複合繊維の海成分を溶解除去する際、十分に除去できなくなるおそれがある。
Next, if necessary, a dry nonwoven fabric can be obtained by dissolving and removing sea components of the sea-island type composite fiber by performing alkali weight reduction processing as described above.
Thus in a dry non-woven fabric obtained, the basis weight of 100 to 1000 g / m 2 (more preferably 120~300g / m 2) it is important that in the range of. When the basis weight is less than 100 g / m 2, it is not preferable because performance such as filter performance and wiping performance cannot be sufficiently obtained. On the contrary, if the basis weight is larger than 1000 g / m 2 , the fibers are not sufficiently entangled when the fibers are entangled with a high-pressure water stream or a needle, or the sea components of the sea-island type composite fibers are dissolved by alkali weight reduction processing. When removing, there is a possibility that it cannot be removed sufficiently.
また、不織布は単層構造に拘る事はなく、繊維構成の異なる多層構造であっても何ら問題ない。更に、短繊維不織布以外に、織物、編物、長繊維不織布等のシート状物を全体重量の２０％未満であれば混入しても問題ない。 Further, the nonwoven fabric is not limited to a single layer structure, and there is no problem even if it has a multilayer structure with different fiber configurations. Furthermore, in addition to the short fiber nonwoven fabric, a sheet-like material such as a woven fabric, a knitted fabric, or a long fiber nonwoven fabric may be mixed as long as it is less than 20% of the total weight.
また、かかる乾式不織布において、通気度が２００ｃｃ／ｃｍ２／ｓｅｃ以下（より好ましくは、８０〜１８０ｃｃ／ｃｍ２／ｓｅｃ）であることが好ましい。該通気度が２００ｃｃ／ｃｍ２／ｓｅｃよりも大きいと、フィルター性能やワイピング性能などの性能が十分に得られないおそれがある。なお、前記通気度はＪＩＳ Ｌ１０９６ ６．２７．１ Ａ法（フラジール法）により測定するものとする。 Moreover, in this dry nonwoven fabric, the air permeability is preferably 200 cc / cm 2 / sec or less (more preferably, 80 to 180 cc / cm 2 / sec). When the air permeability is higher than 200 cc / cm 2 / sec, there is a possibility that performance such as filter performance and wiping performance cannot be obtained sufficiently. The air permeability is measured by JIS L1096 6.27.1 A method (Fragile method).
本発明の乾式不織布には、必要に応じて、常法の染色加工、カレンダー加工、エンボス加工、親水加工、撥水加工、揉み加工、起毛加工、開繊加工（ウォーターニードル等）など適宜施してもよい。 If necessary, the dry nonwoven fabric of the present invention is appropriately subjected to usual dyeing processing, calendering processing, embossing processing, hydrophilic processing, water repellent processing, kneading processing, raising processing, opening processing (water needle, etc.). Also good.
本発明の乾式不織布は、極細ポリエステル繊維が含まれ、かつ地合いが均一であるので、例えば、ワイパー、フィルター、研磨材、断熱材、吸音材、車両内装材、土木用資材、農業用資材など各種用途に使用される。特に、前記乾式不織布をフィルターおよびワイパーに用いると優れたフィルター性能およびワイピング性能が得られ好ましい。 Since the dry nonwoven fabric of the present invention contains ultra-fine polyester fibers and has a uniform texture, for example, wipers, filters, abrasives, heat insulating materials, sound absorbing materials, vehicle interior materials, civil engineering materials, agricultural materials, etc. Used for applications. In particular, it is preferable to use the dry nonwoven fabric for a filter and a wiper because excellent filter performance and wiping performance can be obtained.
次に本発明の実施例及び比較例を詳述するが、本発明はこれらによって限定されるものではない。なお、実施例中の各測定項目は下記の方法で測定した。 Next, although the Example and comparative example of this invention are explained in full detail, this invention is not limited by these. In addition, each measurement item in an Example was measured with the following method.
（１）溶融粘度
乾燥処理後のポリマーを紡糸時のルーダー溶融温度に設定したオリフィスにセットして５分間溶融保持したのち、数水準の荷重をかけて押し出し、そのときのせん断速度と溶融粘度をプロットする。そのプロットをなだらかにつないで、せん断速度−溶融粘度曲線を作成し、せん断速度が１０００秒−１の時の溶融粘度を見た。
（２）溶解速度測定
海成分および島成分のポリマーを、各々、径０．３ｍｍ、長さ０．６ｍｍのキャピラリーを２４孔もつ口金から吐出し、１０００〜２０００m/分の紡糸速度で引き取って得た未延伸糸を残留伸度が３０〜６０％の範囲になるように延伸して、８３ｄｔｅｘ／２４フィラメントのマルチフィラメントを作成した。これを所定の溶剤および溶解温度で浴比１００として、溶解時間と溶解量から減量速度を算出した。
（３）島径との測定
透過型電子顕微鏡ＴＥＭで、倍率３００００倍で繊維断面写真を撮影し、測定した。ＴＥＭの機械によっては測長機能を活用して測定し、また無いＴＥＭについては、撮った写真を拡大コピーして、縮尺を考慮した上で定規にて測定すればよい。ただし、繊維径は、繊維断面におけるその外接円の直径を用いた（ｎ数５の平均値）。
（４）繊維長
走査型電子顕微鏡（ＳＥＭ）により、海成分溶解除去前の超極細短繊維を基盤上に寝かせた状態とし、２０〜５００倍で測定した。ＳＥＭの測長機能を活用して測定した（ｎ数５の平均値）。
（５）引張り強さ及び伸び率
ＪＩＳ Ｌ１９１３（一般短繊維不織布試験方法）に基づいて実施した。
（６）目付
ＪＩＳ Ｌ１９１３（一般短繊維不織布試験方法）に基づいて実施した。
（７）厚み
ＪＩＳ Ｌ１９１３（一般短繊維不織布試験方法）に基づいて実施した。
（８）密度
ＪＩＳ Ｌ１９１３（一般短繊維不織布試験方法）に基づいて実施した。
（９）通気性
ＪＩＳ Ｌ１９１３（一般短繊維不織布試験方法）に基づいて実施した。
（１０）地合い
出来上がったサンプルの表面の状態を目視にて４段階判定を実施した（地合いが良いものから順に、◎、○、△、×）。
(1) Melt Viscosity The polymer after drying treatment is set in an orifice set at the melter melting temperature at the time of spinning, melted and held for 5 minutes, and then extruded with several levels of load. The shear rate and melt viscosity at that time are determined. Plot. The plot was gently connected to create a shear rate-melt viscosity curve, and the melt viscosity when the shear rate was 1000 seconds -1 was observed.
(2) Dissolution rate measurement Obtained by discharging the sea component and island component polymers from a die having a diameter of 0.3 mm and a length of 0.6 mm from a die having 24 holes and spinning at a spinning speed of 1000 to 2000 m / min. The undrawn yarn was drawn so that the residual elongation was in the range of 30 to 60% to prepare a multifilament of 83 dtex / 24 filament. Using this as a bath ratio of 100 at a predetermined solvent and dissolution temperature, the rate of weight loss was calculated from the dissolution time and the dissolution amount.
(3) Measurement with Island Diameter A transmission electron microscope TEM was used to take and measure a fiber cross-sectional photograph at a magnification of 30000 times. Depending on the TEM machine, the length measurement function is used for measurement, and for a TEM that does not exist, the photograph taken may be enlarged and copied with a ruler after taking the scale into consideration. However, the diameter of the circumscribed circle in the fiber cross section was used as the fiber diameter (average value of n number 5).
(4) Fiber length Using a scanning electron microscope (SEM), the ultrafine fibers before the sea component dissolution and removal were placed on the base and measured at 20 to 500 times. Measurement was performed by utilizing the length measurement function of SEM (average value of n number 5).
(5) Tensile strength and elongation rate It implemented based on JIS L1913 (general short fiber nonwoven fabric test method).
(6) Weight per unit It implemented based on JIS L1913 (general short fiber nonwoven fabric test method).
(7) Thickness Measured based on JIS L1913 (General Short Fiber Nonwoven Fabric Test Method).
(8) Density It implemented based on JIS L1913 (general short fiber nonwoven fabric test method).
(9) Breathability Implemented based on JIS L1913 (general short fiber nonwoven fabric test method).
(10) Texture The surface state of the finished sample was visually determined in four stages (in order of good texture, ◎, ○, Δ, ×).
［実施例１］
島成分に２８５℃での溶融粘度が１２０Ｐａ・ｓｅｃのポリエチレンテレフタレート、海成分に２８５℃での溶融粘度が１３５Ｐａ・ｓｅｃである平均分子量４０００のポリエチレングリコールを４重量％、５−ナトリウムスルホイソフタル酸を９ｍｏｌ％共重合した改質ポリエチレンテレフタレート（溶解速度比（海／島）＝２３０）を使用し、海：島＝１０：９０の重量比率で島数４００の口金を用いて紡糸し、紡糸速度１５００ｍ／ｍｉｎで引き取った。アルカリ減量速度差は１０００倍であった。これを３．９倍に延伸した後（複合繊維の単繊維径２５μｍ（丸断面）、島成分の径７５０ｎｍ（丸断面））、押し込み捲縮機を用いて、繊維に捲縮を付与させた後に、ギロチンカッターで４４ｍｍにカットした極細ポリエステル前駆体繊維（ポリエステル繊維Ａ用）とした。この前駆体繊維と常法により製造されたポリエチレンテレフタレート繊維（１．７ｄｔｅｘ×４４ｍｍ、丸断面、ポリエステル繊維Ｂ）を１０／９０の比率で混綿した後にローラーカードを用いて均一なウェブを得た。このウェブを秤量し、ニードルパンチ機を用いて絡合処理を施し、乾式不織布を得た。その際、絡合処理の条件は下記の通りとした。
針：４０番レギュラー針
１回目（表から裏）：５０Ｐ／ｃｍ２、＋６．５ｍｍ
２回目（裏から表）：１００Ｐ／ｃｍ２、＋７．５ｍｍ
３回目（表から裏）：７５Ｐ／ｃｍ２、＋６．５ｍｍ
[Example 1]
Polyethylene terephthalate having a melt viscosity at 285 ° C. of 120 Pa · sec as the island component, polyethylene glycol having an average molecular weight of 4000 having a melt viscosity of 135 Pa · sec at 285 ° C. as the sea component, and 4% by weight of 5-sodium sulfoisophthalic acid. Using 9 mol% copolymerized modified polyethylene terephthalate (dissolution rate ratio (sea / island) = 230), spinning was performed using a die having 400 islands at a weight ratio of sea: island = 10: 90, and spinning speed was 1500 m. / Min. The alkali weight loss rate difference was 1000 times. After stretching this to 3.9 times (single fiber diameter of composite fiber 25 μm (round section), island component diameter 750 nm (round section)), crimping was applied to the fiber using an indentation crimper. Later, an ultrafine polyester precursor fiber (for polyester fiber A) cut to 44 mm with a guillotine cutter was obtained. This precursor fiber and polyethylene terephthalate fiber (1.7 dtex × 44 mm, round cross section, polyester fiber B) produced by a conventional method were blended at a ratio of 10/90, and then a uniform web was obtained using a roller card. This web was weighed and entangled with a needle punch machine to obtain a dry nonwoven fabric. At that time, the conditions for the entanglement treatment were as follows.
Needle: 40th regular needle 1st time (from front to back): 50 P / cm 2 , +6.5 mm
Second time (front to back): 100 P / cm 2 , +7.5 mm
3rd time (from front to back): 75 P / cm 2 , +6.5 mm
次いで、これを、４％ＮａＯＨ水溶液（７５℃、３０分）で処理（前駆体繊維が約１０％減量）する事により、前駆体繊維（複合繊維）の海成分を除去することにより、単繊維径７５０ｎｍのポリエステル繊維とした後に、エアースルー乾燥機にて乾燥を行った。得られた乾式不織布において、不織布の目付け２００ｇ／ｍ２、ポリエステル繊維Ａの単繊維径ＤＡが７５０ｎｍ、繊維長ＬＡが４４ｍｍ、単繊維径（ＤＡ）ｎｍに対する繊維長（ＬＡ）ｎｍの比（ＬＡ／ＤＡ）が５８６６７、ポリエステル繊維Ｂの単繊維径（ＤＢ）が１２μｍ、繊維長（ＬＢ）が４４ｍｍ、ポリエステル繊維Ａとポリエステル繊維Ｂとの重量比（ポリエステル繊維Ａ：ポリエステル繊維Ｂ）９：９１であった。得られた乾式不織布の物性を表１に示す。
次いで、前記乾式不織布を用いて、フィルターおよびワイパーを得て評価したところ、それぞれ優れたフィルター性能およびワイピング性能を有するものであった。
Next, by treating this with a 4% NaOH aqueous solution (75 ° C., 30 minutes) (precursor fiber is reduced by about 10%), by removing the sea component of the precursor fiber (composite fiber), the single fiber After the polyester fiber having a diameter of 750 nm was dried with an air-through dryer. In the obtained dry nonwoven fabric, the basis weight of the nonwoven fabric is 200 g / m 2 , the single fiber diameter DA of the polyester fiber A is 750 nm, the fiber length LA is 44 mm, and the ratio of the fiber length (LA) nm to the single fiber diameter (DA) nm (LA / DA) is 58667, the single fiber diameter (DB) of the polyester fiber B is 12 μm, the fiber length (LB) is 44 mm, and the weight ratio of the polyester fiber A to the polyester fiber B (polyester fiber A: polyester fiber B) 9:91 Met. The physical properties of the obtained dry nonwoven fabric are shown in Table 1.
Subsequently, when the filter and wiper were obtained and evaluated using the dry nonwoven fabric, they had excellent filter performance and wiping performance, respectively.
［実施例２］
実施例１で用いた前駆体繊維とポリエステル繊維の比率を３０／７０に変更した以外は同様の条件にて、不織布を製造した。ポリエステル繊維Ａとポリエステル繊維Ｂとの重量比（ポリエステル繊維Ａ：ポリエステル繊維Ｂ）２８：７２であった。得られた不織布の物性を表１に示す。
次いで、前記乾式不織布を用いて、フィルターおよびワイパーを得て評価したところ、それぞれ優れたフィルター性能およびワイピング性能を有するものであった。
[Example 2]
A nonwoven fabric was produced under the same conditions except that the ratio of the precursor fiber and the polyester fiber used in Example 1 was changed to 30/70. The weight ratio of polyester fiber A to polyester fiber B (polyester fiber A: polyester fiber B) was 28:72. Table 1 shows the physical properties of the obtained nonwoven fabric.
Subsequently, when the filter and wiper were obtained and evaluated using the dry nonwoven fabric, they had excellent filter performance and wiping performance, respectively.
［実施例３］
実施例１と同じ繊維、同じ比率であるのに対して、目付を変更（３００ｇ／ｍ２）しした以外は同様の条件にて、不織布を製造した。得られた不織布の物性を表１に示す。
次いで、前記乾式不織布を用いて、フィルターおよびワイパーを得て評価したところ、それぞれ優れたフィルター性能およびワイピング性能を有するものであった。
[Example 3]
A nonwoven fabric was produced under the same conditions as in Example 1 except that the basis weight was changed (300 g / m 2 ) while the same ratio and ratio were used. Table 1 shows the physical properties of the obtained nonwoven fabric.
Subsequently, when the filter and wiper were obtained and evaluated using the dry nonwoven fabric, they had excellent filter performance and wiping performance, respectively.
［比較例１］
実施例１において、用いた前駆体繊維とポリエステル繊維の比率を８０／２０に変更した以外は実施例１と同様の条件で不織布を製造した。ポリエステル繊維Ａとポリエステル繊維Ｂとの重量比（ポリエステル繊維Ａ：ポリエステル繊維Ｂ）７８：２２であった。得られた不織布の物性を表１に示す。
次いで、前記乾式不織布を用いて、フィルターおよびワイパーを得て評価したところ、地合いが悪く、実施例１で得られたものよりも劣るものであった。
[Comparative Example 1]
In Example 1, the nonwoven fabric was manufactured on the conditions similar to Example 1 except having changed the ratio of the used precursor fiber and polyester fiber into 80/20. The weight ratio of polyester fiber A to polyester fiber B (polyester fiber A: polyester fiber B) was 78:22. Table 1 shows the physical properties of the obtained nonwoven fabric.
Subsequently, when a filter and a wiper were obtained and evaluated using the dry nonwoven fabric, the texture was poor and was inferior to that obtained in Example 1.
［比較例２］
実施例１において、実施例１で用いたポリエステル繊維のみを用いる以外は同様の条件で不織布を製造した。得られた不織布の物性を表１に示す。かかる不織布には極細繊維が含まれていないので、フィルター性能やワイピング性能に劣るものであった。
[Comparative Example 2]
In Example 1, the nonwoven fabric was manufactured on the same conditions except using only the polyester fiber used in Example 1. FIG. Table 1 shows the physical properties of the obtained nonwoven fabric. Since such a nonwoven fabric does not contain ultrafine fibers, it was inferior in filter performance and wiping performance.
本発明によれば、極細ポリエステル繊維を含み、かつ地合いが均一な乾式不織布、および該乾式不織布を用いてなる繊維製品が提供され、その工業的価値は極めて大である。 ADVANTAGE OF THE INVENTION According to this invention, the dry nonwoven fabric containing an ultrafine polyester fiber and a uniform texture and the textiles using this dry nonwoven fabric are provided, The industrial value is very large.
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