JP6732975B2 - 捲縮した微細繊維を含む、均一性が改善されたスパンボンド不織布 - Google Patents
捲縮した微細繊維を含む、均一性が改善されたスパンボンド不織布 Download PDFInfo
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- JP6732975B2 JP6732975B2 JP2019015078A JP2019015078A JP6732975B2 JP 6732975 B2 JP6732975 B2 JP 6732975B2 JP 2019015078 A JP2019015078 A JP 2019015078A JP 2019015078 A JP2019015078 A JP 2019015078A JP 6732975 B2 JP6732975 B2 JP 6732975B2
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- nonwoven fabric
- polymer
- melt flow
- flow rate
- polymeric material
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- 239000000835 fiber Substances 0.000 title claims description 81
- 239000004745 nonwoven fabric Substances 0.000 title claims description 46
- 239000000463 material Substances 0.000 claims description 85
- 229920000642 polymer Polymers 0.000 claims description 52
- 229920005601 base polymer Polymers 0.000 claims description 40
- 229920005629 polypropylene homopolymer Polymers 0.000 claims description 33
- 239000004743 Polypropylene Substances 0.000 claims description 21
- 238000002844 melting Methods 0.000 claims description 18
- 230000008018 melting Effects 0.000 claims description 18
- -1 polypropylene Polymers 0.000 claims description 18
- 239000000155 melt Substances 0.000 claims description 17
- 238000012545 processing Methods 0.000 claims description 17
- 229920001155 polypropylene Polymers 0.000 claims description 14
- 238000000605 extraction Methods 0.000 claims description 10
- 238000000034 method Methods 0.000 claims description 10
- 239000004744 fabric Substances 0.000 claims description 9
- 239000012748 slip agent Substances 0.000 claims description 8
- 229920001169 thermoplastic Polymers 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000004416 thermosoftening plastic Substances 0.000 claims description 6
- 239000002861 polymer material Substances 0.000 claims description 5
- 229920002959 polymer blend Polymers 0.000 claims description 4
- 229920005638 polyethylene monopolymer Polymers 0.000 claims description 3
- 230000036316 preload Effects 0.000 claims description 3
- 239000004750 melt-blown nonwoven Substances 0.000 claims description 2
- 240000002853 Nelumbo nucifera Species 0.000 claims 1
- 235000006508 Nelumbo nucifera Nutrition 0.000 claims 1
- 235000006510 Nelumbo pentapetala Nutrition 0.000 claims 1
- 229920001038 ethylene copolymer Polymers 0.000 claims 1
- 239000003570 air Substances 0.000 description 40
- 230000000052 comparative effect Effects 0.000 description 25
- 239000000654 additive Substances 0.000 description 16
- 238000009826 distribution Methods 0.000 description 15
- 230000000996 additive effect Effects 0.000 description 11
- 229920005653 propylene-ethylene copolymer Polymers 0.000 description 11
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- 238000004458 analytical method Methods 0.000 description 7
- 238000001816 cooling Methods 0.000 description 7
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- 239000000203 mixture Substances 0.000 description 6
- 238000002788 crimping Methods 0.000 description 5
- 238000002474 experimental method Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 230000002902 bimodal effect Effects 0.000 description 4
- 230000006872 improvement Effects 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 229920000098 polyolefin Polymers 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- 239000000178 monomer Substances 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 235000004035 Cryptotaenia japonica Nutrition 0.000 description 2
- 206010021639 Incontinence Diseases 0.000 description 2
- 102000007641 Trefoil Factors Human genes 0.000 description 2
- 235000015724 Trifolium pratense Nutrition 0.000 description 2
- 229940053200 antiepileptics fatty acid derivative Drugs 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000007596 consolidation process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- UAUDZVJPLUQNMU-KTKRTIGZSA-N erucamide Chemical compound CCCCCCCC\C=C/CCCCCCCCCCCC(N)=O UAUDZVJPLUQNMU-KTKRTIGZSA-N 0.000 description 2
- 238000005469 granulation Methods 0.000 description 2
- 230000003179 granulation Effects 0.000 description 2
- 150000001451 organic peroxides Chemical class 0.000 description 2
- 238000010791 quenching Methods 0.000 description 2
- 239000012925 reference material Substances 0.000 description 2
- 230000035945 sensitivity Effects 0.000 description 2
- 239000000779 smoke Substances 0.000 description 2
- 238000003892 spreading Methods 0.000 description 2
- 230000007480 spreading Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- UAUDZVJPLUQNMU-UHFFFAOYSA-N Erucasaeureamid Natural products CCCCCCCCC=CCCCCCCCCCCCC(N)=O UAUDZVJPLUQNMU-UHFFFAOYSA-N 0.000 description 1
- 239000004594 Masterbatch (MB) Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 241001481789 Rupicapra Species 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
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- 238000003776 cleavage reaction Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- HBGGXOJOCNVPFY-UHFFFAOYSA-N diisononyl phthalate Chemical compound CC(C)CCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCC(C)C HBGGXOJOCNVPFY-UHFFFAOYSA-N 0.000 description 1
- 238000005315 distribution function Methods 0.000 description 1
- 239000000284 extract Substances 0.000 description 1
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- 239000002657 fibrous material Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 150000004668 long chain fatty acids Chemical class 0.000 description 1
- FATBGEAMYMYZAF-KTKRTIGZSA-N oleamide Chemical compound CCCCCCCC\C=C/CCCCCCCC(N)=O FATBGEAMYMYZAF-KTKRTIGZSA-N 0.000 description 1
- FATBGEAMYMYZAF-UHFFFAOYSA-N oleicacidamide-heptaglycolether Natural products CCCCCCCCC=CCCCCCCCC(N)=O FATBGEAMYMYZAF-UHFFFAOYSA-N 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920005606 polypropylene copolymer Polymers 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000011002 quantification Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000007017 scission Effects 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000004677 spark ionization mass spectrometry Methods 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 235000021122 unsaturated fatty acids Nutrition 0.000 description 1
- 150000004670 unsaturated fatty acids Chemical class 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Classifications
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2509/00—Medical; Hygiene
- D10B2509/02—Bandages, dressings or absorbent pads
- D10B2509/026—Absorbent pads; Tampons; Laundry; Towels
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Nonwoven Fabrics (AREA)
- Multicomponent Fibers (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
- Artificial Filaments (AREA)
Description
第1の実験群を以下の表1にまとめている。
第2の実験群を以下の表5にまとめている。
プロピレン添加剤を少量添加すると(実施例19)、さらに高いキャビン圧力を安定的に使用してさらに低デニールの材料を得ることができる材料の組み合わせが得られる。さらにデニールが小さくなっても、材料の厚みは、本質的に変わらないままである。本発明のいくつかの実施例において、引張特性は、比較例C16の参照材料よりも向上している。また、いくつかの例では、TSMD及びTSCDの両方において増加が認められる。本発明の全ての実施例において、TSMD及びTSCDは、目付が小さい場合があるにも関わらず、少なくとも減少していない。
Claims (15)
- 捲縮した多成分繊維を有し、前記多成分繊維の第1の成分が、熱可塑性の第1のベースポリマーを含む熱可塑性の第1のポリマー材料からなり、前記多成分繊維の第2の成分が、前記第1のベースポリマーとは異なる熱可塑性の第2のベースポリマーを含む熱可塑性の第2のポリマー材料からなる、スパンボンド不織布であって、
前記第1のベースポリマー及び前記第2のベースポリマーのメルトフローレートは、230℃及び2.16kgの条件でISO1133に準拠して測定すると15g/10分〜60g/10分であり、
前記第1のポリマー材料又は前記第2のポリマー材料のうち少なくとも1つは、それぞれのベースポリマーに加えて、さらに、1重量%〜10重量%の高メルトフローレートポリマーを含むポリマーブレンドであり、
前記高メルトフローレートポリマーのメルトフローレートは、230℃及び2.16kgの条件でISO1133に準拠して測定すると600g/10分〜3000g/10分であり、
前記多成分繊維は、線質量密度が1.5デニール未満であり、
前記多成分繊維の平均捲縮数は、日本工業規格JIS L−1015−1981に準拠して引張前負荷2mg/デニールで測定すると、繊維1cmあたり、少なくとも8つの範囲である、スパンボンド不織布。 - 請求項1に記載のスパンボンド不織布において、
前記高メルトフローレートポリマーの融点は、ISO11357−3に準拠して測定すると、120℃よりも高い、スパンボンド不織布。 - 請求項1又は2に記載のスパンボンド不織布において、
1重量%〜10重量%の前記高メルトフローレートポリマーが、前記第1のポリマー材料と前記第2のポリマー材料との両方に添加されている、スパンボンド不織布。 - 請求項1〜3のいずれか1項に記載のスパンボンド不織布において、
前記高メルトフローレートポリマーの前記メルトフローレートは、230℃及び2.16kgの条件でISO1133に準拠して測定すると750g/10分よりも高い、スパンボンド不織布。 - 請求項1〜4のいずれか1項に記載のスパンボンド不織布において、
前記高メルトフローレートポリマーの前記メルトフローレートは、230℃及び2.16kgの条件でISO1133に準拠して測定すると2200g/10分未満である、スパンボンド不織布。 - 請求項1〜5のいずれか1項に記載のスパンボンド不織布において、
前記第1のポリマー材料及び/又は前記第2のポリマー材料への前記高メルトフローレートポリマーの添加量が、3重量%〜9重量%である、スパンボンド不織布。 - 請求項1〜6のいずれか1項に記載のスパンボンド不織布において、
前記多成分繊維の線質量密度が、0.6デニール以上である、スパンボンド不織布。 - 請求項1〜7のいずれか1項に記載のスパンボンド不織布において、
前記第1のベースポリマー及び/又は前記第2のベースポリマーは、ポリプロピレンホモポリマー、ポリエチレンホモポリマー及びポリプロピレン−エチレンコポリマーからなる群から選択される、スパンボンド不織布。 - 請求項1〜8のいずれか1項に記載のスパンボンド不織布において、
前記高メルトフローレートポリマーはポリプロピレンホモポリマーである、スパンボンド不織布。 - 請求項1〜9のいずれか1項に記載のスパンボンド不織布において、
前記第1及び/又は第2のポリマー材料はすべり剤をさらに有し、
前記すべり剤は、各前記ポリマー材料の総重量に基づいて、5000ppmまでの量で各前記ポリマー材料に存在する、スパンボンド不織布。 - 紡糸口金、引抜チャネル及び移動ベルトを有する少なくとも2つの押出成形機を備える装置において、請求項1〜10のいずれか1項に記載のスパンボンド不織布を製造する方法であって、
繊維が、前記紡糸口金内で紡糸され、前記引抜チャネルで引き抜かれ、前記移動ベルト上に堆積され、
前記装置は、加圧加工用空気キャビンを備え、
加工用空気が、前記加圧加工用空気キャビンから前記引抜チャネルを通って進行して繊維を引き抜き、
周囲圧力と、前記加圧加工用空気キャビン内の圧力との圧力差を、少なくとも4000パスカルとするか前記引抜チャネル内の最大空気速度を少なくとも70m/sとするか、の少なくとも一方である、方法。 - 請求項11に記載の方法において、
前記周囲圧力と、前記加圧加工用空気キャビン内の圧力との前記圧力差を、最大で8000パスカルとするか、
前記引抜チャネル内の前記最大空気速度を、最大で110m/sとするか、
前記押出成形機の少なくとも一方の温度を、240℃〜285℃とするか、の少なくとも1つである、方法。 - 少なくとも1つの層が請求項1〜10のいずれか1項に記載のスパンボンド不織布からなる、多層布地。
- 少なくとも2つのスパンボンド不織布層(S)と、少なくとも1つのメルトブロー不織布層(M)とをSMS構造で含む、請求項13に記載の多層布地。
- 請求項1〜10のいずれか1項に記載のスパンボンド不織布、又は、請求項13又は14に記載の多層布地を含む、衛生製品。
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